EECU (D12B and D12C), Breakout Box

TSI
Number 030-500
Vehicle Management System Vectro II From 1998
PV776-TSP144528
Foreword
The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to June 2001. The products are under continuous development. Vehicles and components produced after the above date may therefore have different specications and repair methods. When this is believed to have a signicant 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 S.R.T. (Standard Repair Time). Service procedures which do not include an operation number in the title are for general information and no reference is made to an S.R.T. The following levels of observations, cautions and warnings are used in this Service Documentation: Note: Indicates a procedure, practice, or condition that must be followed in order to have the vehicle or component function in the manner intended. Caution: Indicates an unsafe practice where damage to the product could occur. Warning: Indicates an unsafe practice where personal injury or severe damage to the product could occur. Danger: Indicates an unsafe practice where serious personal injury or death could occur.
Volvo Trucks North America, Inc.

Greensboro, NC USA
Order number: PV776-144528
2001 Volvo Trucks North America, Inc., Greensboro, NC USA
All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc.
Contents
General .................................................................................................... 7 Vehicle Management System ................................................................ 7 Engine Control System Glossary ........................................................ 8 Specications ....................................................................................... Description of Signals .......................................................................... EECU (D7C) and Breakout Box Connected in Series Between EECU and Wiring Harness ............................................................... EECU, D7C, with Breakout Box Connected to Wiring Harness Only EECU (D12B and D12C), Breakout Box Connected in Series Between EECU and Wiring Harness ..................................................... EECU (D12B and D12C), Breakout Box Connected to Wiring Harness Only ..................................................................................... Pinouts ................................................................................................. Engine Electronic Control Unit (EECU) ............................................ Pinouts ................................................................................................. Vehicle Electronic Control Unit(VECU) ............................................. Schematic ............................................................................................ D12B .................................................................................................. Schematic ............................................................................................ D12C ................................................................................................. Schematic ............................................................................................ D7C ................................................................................................... Schematic ............................................................................................ VECU ................................................................................................. 10 10 10 13 16 19 22 22 26 26 28 28 29 29 30 30 31 31
Tools ...................................................................................................... 33 Special Tools ....................................................................................... 33 Other Special Equipment .................................................................... 35 Design and Function ........................................................................... Vehicle Management System .............................................................. Strategy ............................................................................................. Conventional Control Systems .......................................................... Data Link System .............................................................................. Data Links, Design and Function ...................................................... Diagnostic Connector ........................................................................ Communication Equipment ............................................................... Instrument Cluster ............................................................................. Vehicle Electronic Control Unit (VECU) ............................................ Engine Electronic Control Unit .......................................................... ABS Brake System ECU ................................................................... SRS Airbag ECU ............................................................................... Transmission ECU ............................................................................. Breakout Boxes and Harnesses ........................................................ VECU Overview ................................................................................ VECU Functions ................................................................................ Sensor Locations ............................................................................... Control Unit Locations ....................................................................... Fuses and Relays .............................................................................. Troubleshooting ................................................................................... Fault Code Troubleshooting ................................................................... Message and Parameter Descriptions ................................................ FMI Table ............................................................................................. Reading/Clearing Fault Codes .......................................................... 37 37 37 37 38 39 47 48 49 50 51 63 64 65 66 67 68 73 77 81 85 85 85 87 88 1
Fault Tracing Strategy ....................................................................... 88 MID 128 EECU ...................................................................................... 92 MID 128 Fault Code Table .................................................................. 92 MID 128 PID 45 Preheater Status ...................................................... 96 Fault Codes ....................................................................................... 96 MID 128 PID 45 Preheater Status, Check .......................................... 97 MID 128 PID 49 ABS Control Status .................................................. 98 Fault Codes ....................................................................................... 98 MID 128 PID 49 ABS Control Status, Check ...................................... 99 MID 128 PID 84 Road Speed ........................................................... 100 Fault Codes ..................................................................................... 100 MID 128 PID 84 Road Speed, Check ............................................... 101 MID 128 PID 85 Cruise Control Status ............................................. 102 Fault Codes ..................................................................................... 102 MID 128 PID 85 Cruise Control Status, Check ................................ 103 MID 128 PID 91 Accelerator Pedal Position ..................................... 104 Fault Codes ..................................................................................... 104 MID 128 PID 91 Accelerator Pedal Position, Check ......................... 105 MID 128 PID 94 Fuel Delivery Pressure ........................................... 106 D7C and D12C ................................................................................ 106 Fault Codes ..................................................................................... 106 MID 128 PID 94 Fuel Delivery Pressure, Check .............................. 107 D7C and D12C ................................................................................ 107 MID 128 PID 100 Engine Oil Pressure ............................................. 110 Fault Codes ..................................................................................... 110 MID 128 PID 100 Engine Oil Pressure, Check ................................. 111 MID 128 PID 102 Boost Pressure ..................................................... 114 Fault Codes ..................................................................................... 114 MID 128 PID 102 Boost Pressure, Check ........................................ 115 MID 128 PID 105 Boost Air Temperature ......................................... 118 Fault Codes ..................................................................................... 118 MID 128 PID 105 Boost Air Temperature, Check ............................. 119 MID 128 PID 107 Air Filter Differential Pressure .............................. 122 Fault Codes ..................................................................................... 122 MID 128 PID 107 Air Filter Differential Pressure, Check .................. 124 MID 128 PID 108 Atmospheric Pressure .......................................... 125 Fault Codes ..................................................................................... 125 MID 128 PID 110 Engine Coolant Temperature ............................... 126 Fault Codes ..................................................................................... 126 MID 128 PID 110 Engine Coolant Temperature, Check ................... 127 MID 128 PID 111 Coolant Level ....................................................... 129 Fault Codes ..................................................................................... 129 MID 128 PID 111 Coolant Level, Check ........................................... 130 MID 128 PID 158 Battery Voltage ..................................................... 131 Fault Codes ..................................................................................... 131 MID 128 PID 158 Battery Voltage, Check ........................................ 132 MID 128 PID 172 Air Inlet Temperature ............................................ 133 Fault Codes ..................................................................................... 133 MID 128 PID 172 Air Inlet Temperature, Check ............................... 134 MID 128 PID 174 Fuel Temperature ................................................. 136 D7C and D12C ................................................................................ 136 Fault Codes ..................................................................................... 136 MID 128 PID 174 Fuel Temperature, Check ..................................... 137 D7C and D12C ................................................................................ 137 MID 128 PID 175 Engine Oil Temperature ....................................... 140 2
Fault Codes ..................................................................................... MID 128 PID 175 Engine Oil Temperature, Check ........................... MID 128 PID 228 Road Speed Sensor Calibration .......................... Fault Codes ..................................................................................... MID 128 PID 228 Road Speed Sensor Calibration, Check .............. MID 128 PPID 86 Engine Brake Torque Percent .............................. Fault Codes ..................................................................................... MID 128 PPID 86 Engine Brake Torque Percent, Check ................. MID 128 PPID 119 High Coolant Temperature ................................. Fault Codes ..................................................................................... MID 128 PPID 119 High Coolant Temperature, Check .................... MID 128 PPID 122 VCB Engine Compression Brake ...................... D12B and D12C .............................................................................. Fault Codes ..................................................................................... MID 128 PPID 122 VCB Engine Compression Brake, Check .......... D12B and D12C .............................................................................. MID 128 PPID 123 EPG 2 ................................................................ D12B and D12C .............................................................................. Fault Codes ..................................................................................... MID 128 PPID 123 EPG 2, Check .................................................... D12B and D12C .............................................................................. MID 128 PPID 124 EPG 1 ................................................................ Fault Codes ..................................................................................... MID 128 PPID 124 EPG 1, Check .................................................... MID 128 SID 1/2/3/4/5/6 Injector ..................................................... D12B and D12C .............................................................................. Fault Codes ..................................................................................... MID 128 SID 1/2/3/4/5/6 Injector, Check .......................................... D12B and D12C .............................................................................. MID 128 SID 17 Fuel Shutoff Valve .................................................. Fault Codes ..................................................................................... MID 128 SID 17 Fuel Shutoff Valve, Check ...................................... D7C only .......................................................................................... MID 128 SID 20 Timing Sleeve ......................................................... D7C only .......................................................................................... Fault Codes ..................................................................................... MID 128 SID 20 Timing Sleeve, Check ............................................ D7C only .......................................................................................... MID 128 SID 21 Engine Position Timing Sensor .............................. D12B and D12C .............................................................................. Fault Codes ..................................................................................... MID 128 SID 21 Engine Position Timing Sensor, Check .................. D12B and D12C .............................................................................. MID 128 SID 21 Needle Lift Sensor ................................................. Fault Codes ..................................................................................... MID 128 SID 21 Needle Lift Sensor, Check ..................................... D7C only .......................................................................................... MID 128 SID 22 Engine Speed Sensor ............................................ Fault Codes ..................................................................................... MID 128 SID 22 Engine Speed Sensor, Check ................................ MID 128 SID 23 Rack Actuator ......................................................... D7C only .......................................................................................... Fault Codes ..................................................................................... MID 128 SID 23 Rack Actuator, Check ............................................. D7C only ..........................................................................................
140 141 144 144 145 146 146 147 148 148 149 151 151 151 152 152 153 153 153 154 154 155 155 156 157 157 157 159 159 161 161 162 162 163 163 163 165 165 166 166 166 167 167 168 168 169 169 170 170 171 172 172 172 174 174 3
MID 128 SID 24 Rack Position Sensor ............................................. D7C only .......................................................................................... Fault Codes ..................................................................................... MID 128 SID 24 Rack Position Sensor, Check ................................. D7C only .......................................................................................... MID 128 SID 33 Fan Control ............................................................. Fault Codes ..................................................................................... MID 128 SID 33 Fan Control, Check ................................................ MID 128 SID 64 Redundant Engine Speed Sensor ......................... D7C only .......................................................................................... Fault Codes ..................................................................................... MID 128 SID 64 Redundant Engine Speed Sensor, Check ............. D7C only .......................................................................................... MID 128 SID 70 Preheater Element 1 .............................................. Fault Codes ..................................................................................... MID 128 SID 70 Preheater Element 1, Check .................................. MID 128 SID 71 Preheater Element 2 .............................................. D12B only ........................................................................................ Fault Codes ..................................................................................... MID 128 SID 71 Preheater Element 2, Check .................................. D12B ................................................................................................ MID 128 SID 230 Idle Validation Switch 1 ........................................ Fault Codes ..................................................................................... MID 128 SID 230 Idle Validation Switch 1, Check ............................ MID 128 SID 231 SAE J1939 Control Link ....................................... Fault Codes ..................................................................................... MID 128 SID 232 5 Volt DC Supply .................................................. Fault Codes ..................................................................................... MID 128 SID 232 5 Volt DC Supply, Check ...................................... MID 128 SID 240 Program Memory ................................................. Fault Codes ..................................................................................... MID 128 SID 250 SAE J1587/1708 Information Link ....................... Fault Codes ..................................................................................... MID 128 SID 253 Data Set Memory EEPROM ................................ Fault Codes ..................................................................................... MID 128 SID 254 Engine Electronic Control Unit (EECU) ............... Fault Codes ..................................................................................... MID 144 VECU .................................................................................... MID 144 Fault Code Table ................................................................ MID 144 PID 29 Second Accelerator Pedal Position Sensor ........... Fault Codes ..................................................................................... MID 144 PID 29 Second Accelerator Pedal Position Sensor, Check MID 144 PID 84 Road Speed ........................................................... Fault Codes ..................................................................................... MID 144 PID 84 Road Speed, Check ............................................... MID 144 PID 91 Accelerator Pedal Position ..................................... Fault Codes ..................................................................................... MID 144 PID 91 Accelerator Pedal Position, Check ......................... MID 144 PID 152 VECU, Number of Resets .................................... Fault Codes ..................................................................................... MID 144 PPID 69 Idle Validation Switch ........................................... Fault Codes ..................................................................................... MID 144 PPID 69 Idle Validation Switch, Check .............................. MID 144 PPID 70 Pedal Switches, Supply ....................................... Fault Codes .....................................................................................
175 175 175 176 176 177 177 178 179 179 179 180 180 181 181 182 183 183 183 184 184 185 185 186 187 187 189 189 190 191 191 192 192 193 193 194 194 196 196 198 198 199 201 201 202 204 204 205 207 207 208 208 209 211 211 4
MID 144 PPID 70 Pedal Switches, Supply, Check ........................... MID 144 PPID 71 Cruise Control and Engine Brake, Supply Switch Fault Codes ..................................................................................... MID 144 PPID 71 Cruise Control and Engine Brake, Supply Switch, Check .................................................................................... MID 144 PPID 72 Accelerator Pedal, Supply Sensors ..................... Fault Codess ................................................................................... MID 144 PPID 72 Accelerator Pedal, Supply Sensors, Check ......... MID 144 PPID 73 Second Accelerator Pedal, Supply Sensors ........ Fault Codes ..................................................................................... MID 144 PPID 73 Second Accelerator Pedal, Supply Sensors, Check ................................................................................................. MID 144 PPID 75 Range Inhibitor, Solenoid Valve Status ............... Fault Codes ..................................................................................... MID 144 PPID 75 Range Inhibitor, Solenoid Valve Status, Check ... MID 144 SID 230 Idle Validation Switch 1 ........................................ Fault Codes ..................................................................................... MID 144 SID 230 Idle Validation Switch 1, Check ............................ MID 144 SID 231 SAE J1939 Control Link ....................................... Fault Codes ..................................................................................... MID 144 SID 231 SAE J1939 Control Link, Check .......................... MID 144 SID 240 Program Memory ................................................. Fault Codes ..................................................................................... MID 144 SID 243 Cruise Control Set Switch .................................... Fault Codes ..................................................................................... MID 144 SID 243 Cruise Control Set Switch, Check ....................... MID 144 SID 250 SAE J1587/1708 Information Link ....................... Fault Codes ..................................................................................... MID 144 SID 250 SAE J1587/1708 Information Link, Check ........... MID 144 SID 253 Data Set Memory EEPROM ................................ Fault Codes ..................................................................................... MID 144 PSID 3 Idle Validation Switch 3 ......................................... Fault Codes ..................................................................................... MID 144 PSID 3 Idle Validation Switch 3, Check .............................
212 215 215 216 220 220 221 223 223 224 226 226 227 229 229 230 232 232 233 234 234 235 235 236 238 238 239 240 240 241 241 242
Service Procedures ........................................................................... 245 Engine ECU, Replacement ................................................................ 245 Feedback Operation Numbers
Group 28
General
General
Vehicle Management System
W2002520
This information covers the Vehicle Management System, which includes VECTRO II electronics, the vehicle ECU, and other control systems used in the vehicle.
Group 28
General
Engine Control System Glossary

ATA American Trucking Association ATDC (After Top Dead Center) The 180 of crankshaft rotation after the piston reaches top center (normal direction of rotation). AC (Alternating Current) An electrical current that alternates level and direction. BTDC (Before Top Dead Center) The 180 of crankshaft rotation before the piston reaches top center (normal direction of rotation). INFO lamp Light that warns the operator of an active diagnostic fault code; also referred to as the diagnostic lamp. Data link An electrical connection for communication with other microprocessor-based devices (such as powertrain control, trip recorders and maintenance systems) that are compatible with the ATA and SAE standard. Diagnostic fault code 9 These codes indicate an electronic system malfunction, indicating a problem with the D12 electrical systems. Diagnostic ash code Codes ashed out in a series via the INFO lamp to indicate an active fault code. DC (Direct Current) An electrical current that ows in one direction only. EEPROM (Electrical Erasable Programmable Read Only Memory) The contents of this type of memory may be electronically erased and new information programmed into the device. EECU (Engine Electronic Control Unit) The computer that controls the power supplied to the engine electronics, monitors and governs engine functions. EUI (Electronic Unit Injector) An injector pump which is mechanically activated and electronically controlled. It combines metering and injecting in a single unit. Engine brake disable system During the time ABS (anti-lock braking system) is active, the engine brake is disabled. 14/15 11 12 13 Failure mode not identiable Defective device or component Uncalibrated device or component Reserved for future assignment 10 Abnormal update Abnormal rate of change

FMI (Failure Mode Identier) Numbers and names used to identify how a system or part failed. FMI 0 1 2 3 4 5 6 7 8 Description Data valid but above normal operating range Data valid but below normal operating range Data erratic, intermittent, or incorrect Voltage above normal Voltage below normal Current below normal or open circuit Current above normal or short circuit Mechanical system not responding properly Abnormal frequency, pulse rate or period
Hz (Hertz) Measure of frequency in cycles per second. MID Message Identication Description Open circuit Condition where an electrical wire or connector is broken, preventing signal or supply voltage from reaching its intended destination. Parameter A programmable value that affects the characteristics or behavior of the engine and/or vehicle.
Group 28
General
PID Parameter Identication code. PTO (Power Takeoff) Operated with the cruise control switches, this mode permits setting a constant engine rpm when the vehicle is not moving. PWM (Pulse Width Modulation) A signal consisting of variable-width pulses at xed intervals to vary; TIME ON versus versus TIME OFF. RAM (Random Access Memory) A memory that has stored information immediately available when addressed. Reference voltage A regulated voltage supplied by the EECU to a sensor, which uses it to generate a signal voltage. Password A group of seven alphanumeric characters designed to restrict access to level-2 parameters. The password is automatically defaulted to seven empty spaces if customer has not specied password. SAE Society of Automotive Engineers. Short circuit A connection of comparatively low resistance, accidentally or intentionally made between two points on a circuit.
SID Subsystem Identication code. Signal A voltage value used to transmit information typically from a sensor to the EECU. Supply voltage A constant voltage that supplies electrical power to a component. It may be generated by the EECU or supplied by the vehicle battery. Throttle Position Sensor (TPS) An electronic sensor that is connected to the accelerator pedal and sends a Pulse Width Modulated signal to the EECU. Vehicle Specication Programming (VSP) VSP consists of two levels of programming: engine conguration (level 1) and customer parameters (level 2). Vehicle Speed Sensor (VSS) An electromagnetic device that measures vehicle speed from the rotation of gear teeth in the drivetrain of the vehicle. VEB (Volvo Engine Brake) Consists of a compression brake (VCB) and an exhaust pressure governor (EPG).
Group 28
Specications
Specications
Description of Signals EECU (D7C) and Breakout Box Connected in Series Between EECU and Wiring Harness
For the measurements below, the following applies:
Breakout box J-41132 connected between connector EA or EB and the EECU. Jumper harness J43233 connected between connector EA or EB and the EECU.
The EECU connected. Ignition key in ON position. Engine not running. Measuring voltage.
W2002710
Fig. 3: EECU voltage check, EB
W2003555
Fig. 1: EECU with pinouts
W2002712
Fig. 2: EECU voltage check, EA B+ = battery voltage

Connection EA1 Signal type Measuring points Ignition key in the ON position

Other
Oil temperature sensor, signal
EA1 - EA5
3.0 V (+20 C/68 F) 0.4 V (+100 C/212 F) 2.6 V (+20 C/68 F) 1.6 V (+40 C/104 F) 1.1 V (sea level)

EA2
Intake manifold temperature sensor, signal Intake manifold pressure sensor, signal Supply to sensors (5 V), + Signal ground to sensors, Not currently used Redundant engine speed sensor, + Rack drive PWM, + Timing sleeve PWM, +
EA2 - EA5
EA3
EA3 - EA5
EA4 EA5 EA6 EA7 EA8 EA9
EA4 - EA5
4.8 - 5.15 V
10
Group 28
Specications
Connection EA10 EA11 EA12 EA13
Signal type
Measuring points
Ignition key in the ON position
Other
Rack drive PWM, Not currently used Not currently used Fuel temperature sensor, signal EA13 - EA5 3.0 V (+20 C/68 F) 2.0 V (+40 C/104 F) 0.5 V (for cold engines)

EA14 EA15 EA16 EA17 EA18 EA19 EA20 EA21 EA22 EA23 EA24 EA25
Oil pressure sensor, signal Needle lift sensor, + Rack position sensor, search coil Rack position sensor, common Redundant engine speed sensor, Not currently used Not currently used Timing sleeve PWM, Not currently used Not currently used Not currently used Coolant temperature sensor, signal
EA14 - EA5
EA25 - EA5
3.0 V (+20 C/68 F) 0.6 V (+85 C/185 F)
EA26 EA27 EA28 EA29 EA30 EA31 EA32 EA33 EA34 EA35 EA36 EB1 EB2 EB3
Not currently used Fuel pressure sensor, signal Needle lift sensor, Rack position sensor, reference coil Engine speed sensor (crank), + Engine speed sensor (crank), Not currently used Not currently used Not currently used Not currently used Not currently used SAE J1939 A Communications link SAE J1939 B Communications link Ambient air temperature sensor, signal Buffered idle validation switch EB1/EB9 EB2/EB9 EB3 - EB13 2-5V 0-3V 2.6 V (+20 C/68 F) 1.2 V (+50 C/122 F) < 4 V (idle) > 8 V (off idle) 55 % of B+ (open) 0 V (closed) Normally closed with the ignition key in the ON position.

EA27-EA5
0.5V (for cold engines)
D12 C
EB4
EB4 - EB9
EB5
Pre-heat sense 1
EB5 - EB9
EB6
Not currently used
11
Group 28
Specications
Connection EB7
Signal type
Measuring points
Other
Coolant level sensor, signal
EB7 - EB8
80% B+ (open) 0 V (closed)
Applies to WX and VN. Normally open with the ignition key in the ON position.
EB8 EB9 EB10 EB11 EB12 EB13 EB14 EB15 EB16 EB17 EB18 EB19 EB20 EB21
Signal ground to sensors, EECU ground, EECU ground, EECU B+ EECU B+ Ambient air temperature sensor Not currently used Not currently used Not currently used Air lter indicator sensor signal Not currently used Not currently used Not currently used Fan control (if equipped with on/off fan) EB21 - EB9 B+ (fan on) 0 V (fan off) Normally ON with the ignition key in the ON position. EB11 - EB9 EB12 - EB10 B+ B+
EB22 EB23 EB24
Not currently used Not currently used EOL Enable EB24 - EB9 < 6 V or O/C (EOL Disable) > 9.6 V (EOL Enable) 0-5V 0-5V
EB25 EB26 EB27 EB28 EB29 EB30 EB31
SAE J1587A/J1708A Information link SAE J1587B/J1708B Information link Not currently used Not currently used Not currently used Not currently used Pre-heating relay, Coil ground
EB25-EB9 EB26-EB9
EB31 - EB9
B+ (pre-heat off) 0 V (pre-heat on)
Normally ON with the ignition key in the ON position.
EB32 EB33 EB34
Not currently used Not currently used Fuel shut-off valve EB34 - EB9 0 V (valve on) > 1.0V (valve off) Normally ON with the ignition key in the ON position. Normally OFF with the ignition key in the ON position.
EB35
EPG 1
EB35 - EB9
B+ (EPG off) 0 V (EPG on)
EB36
Not currently used
12
Group 28
Specications
EECU, D7C, with Breakout Box Connected to Wiring Harness Only

Breakout box J-41132 connected to connector EA or EB. The EECU is not connected. Ignition key must be in the OFF position. Measuring resistance.
W2002713 W2002711
Fig. 5: EECU harness checks, EB
Fig. 4: EECU harness checks, EA
Connection EA1
Signal type
Measuring points
Ignition key in the OFF position 1.9 k

(+20 C/68 F) 100
(+100 C/212 F)

Other
EA1 / EA5
EA2
Intake manifold temperature sensor, signal Intake manifold pressure sensor, signal Sensor supply to (5 V), + Sensors ground , Not currently used Redundant engine speed sensor, + Rack drive PWM, +
EA2 / EA5
6.2 k
(+20 C/68 F) 2.5 k
(+40 C/104 F)

EA3 EA4 EA5 EA6 EA7 EA8
EA7 / EA18 EA8 / EA10 EA8 / alternate ground EA9 / EA21 EA9 / alternate ground EA10 / alternate ground
775 - 945
1.5
open circuit 1.5
open circuit
EA9
Timing sleeve PWM, +
EA10 EA11 EA12 EA13 EA14 EA15 EA16 EA17 EA18 EA19
Rack drive PWM, Not currently used Not currently used Fuel temperature sensor, signal Oil pressure sensor, signal Needle lift sensor, + Rack position sensor, search coil Rack position sensor, common Redundant engine speed sensor, Not currently used
open circuit (see also EA8)
EA13 / EA5
1.9 k
(+20 C/68 F) 800
(+40 C/104 F)

EA15 / EA28 EA16 / EA17
65 - 165 20.0
13
EA18 / EA7
775 - 945
Group 28
Specications
Connection EA20 EA21 EA22 EA23 EA24 EA25 EA26 EA27 EA28 EA29 EA30 EA31 EA32 EA33 EA34 EA35 EA36 EB1 EB2 EB3 EB4 EB5 EB6 EB7 EB8 EB9 EB10 EB11 EB12 EB13 EB14 EB15 EB16 EB17 EB18 EB19 EB20 EB21 EB22 EB23 EB24
Signal type Not currently used Timing sleeve PWM, Not currently used Not currently used Not currently used Coolant temperature sensor, signal Not currently used Fuel pressure sensor Needle lift sensor, Rack position sensor, reference coil Engine speed sensor (crank), + Engine speed sensor (crank), Not currently used Not currently used Not currently used Not currently used Not currently used SAE J1939A Communications link SAE J1939B Communications link Ambient air temperature sensor, signal Buffered idle validation switch Pre-heat sense 1 Not currently used Coolant level sensor, signal Sensor ground EECU ground, EECU ground, EECU, B+ EECU, B+ Ambient air temperature ground Not currently used Not currently used Not currently used Air lter indicator sensor signal Not currently used Not currently used Not currently used Not currently used Not currently used Not currently used EOL Enable
Measuring points
Ignition key in the OFF position
Other
EA21 / alternate ground
open circuit (see also EA9)
EA25 / EA5
1.9 k
(+20 C/68 F) 160
(+85 C/185 F)

D12 C
EA29 / EA17 EA30 / EA31 EA31 / EA30
20.0
775 - 945 775 - 945
EB3 / EB13
6.2 k
(+20 C/68 F) 1.7 k
(+50 C/122 F)

EB5 / EB9
open circuit (open) < 5

(closed)
EB7 / EB8
open circuit (coolant level normal) <1

(coolant level low)
Applies to WX and VN
EB24/EB9
open circuit (open)
14
Group 28
Specications
Connection
Signal type
Measuring points
Other
EB25 / (connection A in 6 pin diagnostics connector) EB25 SAE J1587/J1708 A Information link EB25 / (connection F in 9 pin diagnostics connector) EB26 SAE J1587/J1708 B Information link EB26 / (connection B in the 6 pin diagnostics connector) EB26 / (connection G in the 9 pin diagnostics connector) EB27 EB28 EB29 EB30 EB31 EB32 EB33 EB34 EB35 EB36 Not currently used Not currently used Not currently used Not currently used Pre-heating relay, coil ground Not currently used Not currently used Fuel shut-off valve, include EPG 1, Not currently used
<1
<1
<1
<1
15
Group 28
Specications
EECU (D12B and D12C), Breakout Box Connected in Series Between EECU and Wiring Harness
Breakout box J-41132 connected between connector EA or EB and the EECU. Jumper harness J43233 connected between connector EA or EB and the EECU. The EECU connected. Ignition key in ON position. Engine not running. Measuring voltage.
W2002710 W2002712
Fig. 6: EECU voltage check, EA B+ = battery voltage

Connection EA1 Signal type Measuring points
Fig. 7: EECU voltage check, EB

Other
EA1 / EA5
3.0 V (+20 C/68 F) 0.4 V (+100 C/212 F) 2.6 V (+20 C/68 F) 1.6 V (+40 C/104 F) 1.1 V (sea level)

EA2
Intake manifold temperature sensor, signal Intake manifold pressure sensor, signal Sensor supply (5 V), + Sensor ground Not currently used Engine position sensor (cam), + Not currently used Not currently used Not currently used Unit injector cylinder 1, Unit injector cylinder 1, 2, 3 (90 Volt), + Fuel temperature sensor, signal Oil pressure sensor, signal Not currently used
EA2 / EA5
EA3
EA3 / EA5
EA4 EA5 EA6 EA7 EA8 EA9 EA10 EA11 EA12
EA4 / EA5
4.8 - 5.15 V
EA13 EA14 EA15
D12 C EA14 / EA5 0.5 V (for cold engines)
16
Group 28
Specications
Connection EA16 EA17 EA18 EA19 EA20 EA21 EA22 EA23 EA24
Signal type
Measuring points
Other
Not currently used Not currently used Engine position sensor (cam), Not currently used Not currently used Not currently used Unit injector cylinder 2, Unit injector cylinder 3, Unit injector cylinder 4, 5, 6 (90 Volt), + Coolant temperature sensor, signal EA25 / EA5 3.0 V (+20 C/68 F) 0.6 V (+85 C/185 F)

EA25
EA26 EA27 EA28 EA29 EA30 EA31 EA32 EA33
Not currently used Fuel pressure sensor Not currently used Not currently used Engine speed sensor (crank), + Engine speed sensor (crank), Not currently used VCB, EA33 / alternate ground B+ (VCB off) 0 V (VCB on) Normally OFF with the ignition key in the ON position. D12 C
EA34 EA35 EA36 EB1
Unit injector cylinder 4, Unit injector cylinder 5, Unit injector cylinder 6, SAE J1939 Communications link, can HI SAE J1939 Communications link, can LOW Ambient air temperature sensor, signal Buffered idle validation switch EB1/EB9 2-5V 0-3V 2.6 V (+20 C/68 F) 1.2 V (+50 C/122 F) < 4 V (inactive) > 8 V (active) 55% of B+ (open) 0 V (closed) Normally closed with the ignition key in the ON position.

EB2
EB2/EB9
EB3
EB3 / EB13
EB4
EB4 / EB9
EB5
Pre-heat sense 1 (if equipped)
EB5 / EB9
EB6 EB7
Not currently used Coolant level sensor, signal EB7 / EB8 80% B+ (open) 0 V (closed) VN and VHD. Normally open with the ignition key in the ON position.
EB8 EB9 EB10
Sensor ground EECU ground, EECU ground, -
17
Group 28
Specications
Connection EB11 EB12 EB13 EB14 EB15 EB16
Signal type
Measuring points
Other
EECU B+ EECU B+ Ambient air temperature sensor Not currently used Not currently used Pre-heat sensor 2 (if equipped)
EB11 / EB9 EB12 / EB10
B+ B+
EB16 / EB9
55 % of B+ (open) 0 V (closed)
Normally closed with the ignition key in the ON position.
EB17 EB18 EB19 EB20 EB21
Air lter indicator sensor signal Not currently used Not currently used Not currently used Engine fan control (if equipped with on/off fan), EB21 / EB9 B+ (fan on/solenoid inactive) 0 V (fan off/solenoid active) Normally ON with the ignition key in the ON position.
EB22 EB23 EB24
Not currently used Not currently used EOL Enable EB24 / EB9 < 6 V or O/C (EOL disable) > 9.6 V (EOL Enable)
EB25 EB26 EB27 EB28 EB29 EB30 EB31
SAE J1587/J1708 + Information link SAE J1587/J1708 - Information link Not currently used Not currently used Not currently used Not currently used Pre-heating relay coil ground (if equipped) EB31 / EB9 B+ (pre-heat off) 0 V (pre-heat on) Normally OFF with the ignition key in the ON position. EB25/EB9 EB26/EB9 0-5V 0-5V
EB32 EB33 EB34 EB35
Not currently used Not currently used Not currently used EPG 1 EB35 / EB9 B+ (EPG off) 0 V (EPG on) Normally OFF with the ignition key in the ON position. Normally OFF with the ignition key in the ON position.
EB36
EPG 2
EB36 / EB9
B+ (EPG off) 0 V (EPG on)
18
Group 28
Specications
EECU (D12B and D12C), Breakout Box Connected to Wiring Harness Only
Breakout box J-41132 connected to connector EA or EB. The EECU not connected. Ignition key must be in the OFF position. Measuring resistance.
W2002713 W2002711
Fig. 9: EECU harness checks, EB
Fig. 8: EECU harness checks, EA
Connection EA1
Signal type
Measuring points
Ignition key in the OFF position 1.9 k

(+20 C/68 F) 100
(+100 C/212 F)

Other
EA1 / EA5
EA2
Intake manifold temperature sensor, signal Intake manifold pressure sensor, signal Sensor supply (5 V), + Sensor ground Not currently used Engine position sensor (cam), + Not currently used Not currently used Not currently used Unit injector cylinder 1, Unit injector cylinder 1, 2, 3 (90 Volt), + Fuel temperature sensor, signal Oil pressure sensor, signal Not currently used Not currently used Not currently used Engine position sensor (cam), Not currently used Not currently used
EA2 / EA5
6.2 k
(+20 C/68 F) 2.5 k
(+40 C/104 F)

EA3
EA4 EA5 EA6 EA7 EA8 EA9 EA10 EA11 EA12
EA7 / EA18
775 - 945
EA11 / EA12
1.5 - 2.0
see EA11, EA22 and EA23
EA13 EA14 EA15 EA16 EA17 EA18 EA19 EA20
D12 C
see EA7
19
Group 28
Specications
Connection EA21 EA22 EA23 EA24
Signal type
Measuring points
Other
Not currently used Unit injector cylinder 2, Unit injector cylinder 3, Unit injector cylinder 4, 5, 6 (90 Volt), + Coolant temperature sensor, signal EA25 / EA5 EA22 / EA12 EA23 / EA12 1.5 - 2.0 1.5 - 2.0
see EA34, EA35, and EA36 1.9 k

(+20 C/68 F) 160
(+85 C/185 F)

EA25
EA26 EA27 EA28 EA29 EA30 EA31 EA32 EA33 EA34 EA35 EA36 EB1 EB2 EB3
Fuel pressure sensor, signal Not currently used Not currently used Not currently used Engine speed sensor (crank), + Engine speed sensor (crank), Not currently used VCB, Unit injector cylinder 4, Unit injector cylinder 5, Unit injector cylinder 6, SAE J1939 + Communications link SAE J1939 - Communications link Ambient air temperature sensor, signal Buffered idle validation switch Pre-heat sense 1 (if equipped) EB5 / EB9 open circuit (open) < 5.0
(closed) EB3 / EB13 6.2 k
(+20 C/68 F) 1.7 k
(+50 C/122 F)

D12 C
EA30 / EA31 EA31 / EA30
775 - 945 775 - 945
EA34 / EA24 EA35 / EA24 EA36 / EA24
1.5 - 2.0 1.5 - 2.0 1.5 - 2.0
EB4 EB5
EB6 EB7
Not currently used Coolant level sensor, signal EB7 / EB8 open circuit (coolant level normal) <1
; closed (coolant level low) Applies to WX , VN and VHD
EB8 EB9 EB10 EB11 EB12 EB13 EB14 EB15 EB16
Sensors ground EECU ground, EECU ground, EECU B+ EECU B+ Ambient air temperature sensor Not currently used Not currently used Pre-heat sensor 2 (if equipped) EB16 / EB9 open circuit (open) < 5.0
(closed)
EB17 EB18 EB19
Air lter indicator sensor signal Not currently used Not currently used
20
Group 28
Specications
Connection EB20 EB21
Signal type
Measuring points
Other
Not currently used Engine fan control (if equipped with on/off fan) Not currently used Not currently used EOL Enable EB24/EB9 EB25 / (connection A in the 6 pin diagnostics connector) Open circuit(open) <1
EB22 EB23 EB24
EB25
SAE J1587/J1708 A Information link
EB25 / DCA (connection F in the 9 pin diagnostics connector) EB26 / (connection B in the 6 pin diagnostics connector)
<1
<1
EB26
SAE J1587/J1708 B Information link EB26 / (connection G in the 9 pin diagnostics connector) <1
Not currently used Not currently used Not currently used Not currently used Preheating relay coil ground (if equipped) Not currently used Not currently used Not currently used EPG 1, EPG 2, -
21
Group 28
Specications
Pinouts Engine Electronic Control Unit (EECU)

VOLVO D12B/D12C EECU/EA Connector Cavity
1 2 3 4 5
Color
GN BL/W GR GN/W BN/W
Description
OIL TEMPERATURE BOOST TEMPERATURE BOOST PRESSURE BOOST & OIL PRESSURE COMMON (+) PRESSURE & TEMP. SENSOR COMMON (-)
W3000945
6 7 8-10 11 12 W W Y
NOT USED ENGINE POSITION SENSOR, CAM (+) NOT USED INJECTOR, CYL 1 (-) CYL 1, CYL 2, CYL 3 INJECTOR COMMON, 90 Volt (+)
13 14 15-17 18 19-21 22 23 24
GN BN
FUEL TEMPERATURE (D12C) OIL PRESSURE NOT USED
BN/W
ENGINE POSITION SENSOR, CAM (-) NOT USED
W W W
INJECTOR, CYL 2 (-) INJECTOR, CYL 3 (-) CYL 4, CYL 5, CYL 6 INJECTOR COMMON, 90 Volt (+)
25 26 27 28-29 30 31 32 33 34 35 36
Y/W
COOLANT TEMPERATURE NOT USED
BN
FUEL PRESSURE (D12C) NOT USED
BL/SB BL/R
ENGINE SPEED SENSOR, CRANK (+) ENGINE SPEED SENSOR, CRANK (-) NOT USED
GN/W W W W
VCB SOLENOID VALVE RETURN INJECTOR, CYL 4 (-) INJECTOR, CYL 5 (-) INJECTOR, CYL 6 (-)
Wire Colors:
BL BN GN GR OR P
BLUE BROWN GREEN GRAY ORANGE PINK
R SB VO W Y
RED SOLID BLACK VIOLET WHITE YELLOW
22
Group 28
Specications
VOLVO D12B/D12C EECU/EB Connector Cavity

1 2 3 4
Color
Y GN BL/Y P
Description
DATA LINK J1939 CAN HI DATA LINK J1939 CAN LO AMBIENT AIR TEMPERATURE
W3000945
BUFFERED IDLE VALIDATION SWITCH PREHEAT SENSE 1 NOT USED
5 6 7 8 9 10 11 12 13 14-15 16 17 18-20 21 22-23 24
BL/SB GR/W W W R/SB R/SB V0/W
COOLANT LEVEL WARNING AIR FILTER, COOL LVL COMMON GROUND (-) GROUND (-) POWER SUPPLY (+) POWER SUPPLY (+) AMBIENT AIR TEMP COMMON (-) NOT USED
R/W BL/R
PREHEAT SENSE 2 AIR FILTER INDICATOR NOT USED
GR/R
COOLING FAN CONTROL (-) NOT USED
Y/SB
FACTORY PROGRAMMING (NOT USED) DATA LINK J1708/1587 (+) DATA LINK J1708/1587 (-) NOT USED
25 26 27-30 31 32-34 35 36
GR OR
BL/R
PREHEAT RELAY(Coil Ground) NOT USED
GR/SB GR/W
EPG1 CONTROL EPG2 CONTROL
Wire Colors:
BL BN GN GR OR P
R SB VO W Y
23
Group 28
Specications
VOLVO D7C EECU/EA Connector Cavity

1 2 3 4 5 6 7 8 9 10 11-12 13 14 15 16 17 18 19-20 21 22-24 25 26 27 28 29 30 31 32-36 BN GR/R Y/W BL/SB BL/R Y/W OR GN/BN BN GR/SB BL/R Y/GR BN/W Y Y/R Y/SB GN/BN
Color
GN BL/W GR GN/W BN/W
Description
OIL TEMPERATURE BOOST TEMPERATURE BOOST PRESSURE
BOOST, OIL & FUEL PRESSURE COMMON (+)
W3000945
PRESSURE & TEMP. SENSOR COMMON
NOT USED
REDUNDANT ENGINE SPEED SENSOR (+)
RACK DRIVE, PWM (+) TIMING SLEEVE, PWM RACK DRIVE, PWM (-) NOT USED FUEL TEMPERATURE OIL PRESSURE NEEDLE LIFT SENSOR(+)
RACK POSITION SENSOR, SEARCH COIL
RACK POSITION SENSOR, COMMON

REDUNDANT ENGINE SPEED SENSOR (-)
NOT USED TIMING SLEEVE, PWM (-) NOT USED COOLANT TEMPERATURE NOT USED FUEL PRESSURE NEEDLE LIFT SENSOR (-)
RACK POSITION SENSOR, REFERENCE COIL
ENGINE SPEED SENSOR, CRANK(+) ENGINE SPEED SENSOR, CRANK(-) NOT USED
Wire Colors:
BL BN GN GR OR P
R SB VO W Y
24
Group 28
Specications
VOLVO D7C EECU/EB Connector Cavity

1 2 3 4
Color
Y GN BL/Y P
Description
DATA LINK J1939 CAN HI DATA LINK J1939 CAN LO AMBIENT AIR TEMPERATURE
W3000945
BUFFERED IDLE VALIDATION SWITCH PREHEAT SENSE 1 NOT USED
5 6 7 8
BL/SB GR/W
COOLANT LEVEL WARNING AIR FILTER, COOL LEVEL COMMON (-) GROUND (-) GROUND (-) POWER SUPPLY (+) POWER SUPPLY (+) AMBIENT AIR TEMP COMMON (-) NOT USED
9 10 11 12 13 14-16 17 18-23 24
W W R/SB R/SB V0/W
BL/R
AIR FILTER INDICATOR NOT USED
Y/SB
FACTORY PROGRAMMING (NOT USED) DATA LINK J1708/1587 (+) DATA LINK J1708/1587 (-) NOT USED
25 26 27-30 31 32-33 34 35 36
GR OR
BL/R
PREHEAT RELAY, CONTROL NOT USED
Y/BN GR
FUEL SHUTOFF VALVE CONTROL EPG1 NOT USED
Wire Colors:
BL BN GN GR OR P
R SB VO W Y
25
Group 28
Specications
Pinouts Vehicle Electronic Control Unit(VECU)

Vehicle ECU Connector A-(GREEN) Cavity
1 2 3 4 5 6 567B 284-A
Circuit
564A 563A 562A
Description
CC/PTO SWITCH SET(-) INPUT CC/PTO SWITCH SET(+) INPUT CC/PTO SWITCH ON INPUT NOT USED SERVICE BRAKE SWITCH INPUT 12V STARTER CONTROL SOLENOID FEED ENGINE PREHEAT CIRCUIT PROTECTION FEED CLUTCH SWITCH INPUT PARK CONTROL WIPER MOTOR INTERMITTENT WIPER INPUT SWITCH TO WASHER MOTOR ELECTRONIC GROUND ELECTRONIC ENGINE SWITCHED BATTERY FEED IGNITION SWITCH DR FEED NOT USED
W3002689
245
8 9 10 11 12 13
571 385-A 388 387-C 0XE 18V
14 15-18 19 20 21 22 23 24
196V
300D 629 628
MANUAL FAN SWITCH INPUT ENGINE BRAKE MEDIUM FEED ENGINE BRAKE LOW FEED NOT USED
555 682
IDLE VALIDATION INPUT HIGH REFRIGERANT PRESSURE SWITCH FEED NOT USED
25-28 29 30 573 565A
PTO SWITCH ON INPUT CC/PTO SWITCH RESUME INPUT
26
Group 28
Specications
Vehicle ECU Connector B-(BLUE) Cavity

1 2 312A
Circuit
Description
NOT USED TRANSMISSION AREA INHIBITOR VALVE RETURN
W3002689
3-4 5 6 7 8 553 597 550
NOT USED ECU COMMON 12V OUTPUT VEHICLE SPEED INPUT NOT USED THROTTLE POSITION SENSOR INPUT NOT USED 552 THROTTLE POSITION SENSOR SUPPLY PARKING BRAKE SWITCH INPUT NOT USED 583 POWER CONTROL FROM ENGINE ECU INTERMITTENT WIPER RELAY COIL RETURN IDLE VALIDATION FROM ENGINE ECU RANGE INHIBITOR VALVE RETURN ECU COMMON +12V OUTPUT VEHICLE SPEED RETURN FROM ECU TRANSMISSION LOW RANGE INDICATOR SIGNAL THROTTLE POSITION SENSOR RETURN NOT USED 567A SERVICE BRAKE SWITCH INPUT NOT USED
9 10
11 12-14 15
581
16
389B
17
555A
18 19 20
312C 558 551
21
317B
22
554
23-26 27 28-30
Vehicle ECU Connector C-(GREEN) Cavity

1 2 3 4 5
Circuit
401-D 400-D 408-B 406-B 407-B
Description
DATA LINK J1708 (-) DATA LINK J1708 (+)
W3002690
DATA LINK J1939 SHIELD DATA LINK J1939 CAN HI DATA LINK J1939 CAN LOW
27
Group 28
Specications
Schematic D12B
W2002827
28
Group 28
Specications
Schematic D12C
W2003348
29
Group 28
Specications
Schematic D7C
W2002826
30
Group 28
Specications
Schematic VECU
W3003497
31
32
Group 28
Tools
Tools
Special Tools
The following special tools are required for work with the D12 electronic control system. The 3917916 VOLVO breakout kit, along with its components, is available from Volvo Truck. When requesting tools, provide the appropriate part number. Part numbers beginning with J are available from Kent-Moore.
W2003598
See list on next page for information about the tools in the picture.
33
Group 28
Tools
9998534 J-39200 J-43147 9998482 J-41132 J-42472 J-43233 J-38748
4pin breakout harness digital multimeter 2pin breakout harness Guage for inspection of control unit connector 36pin breakout box 2pin breakout harness 36pin jumper 7pin fuel injection pump breakout box
9809687 9809678 9809685 J-43234 9998551/J43340
AC/DC power supply for PC toll.(optional) 12 Pin DIN Connector cable-alternative programming cable for EECU Power extension cable used together w/9808635. Adapter(Kent Moore). 60 Pin Breakout Box/Overlay.
34
Group 28
Tools
Other Special Equipment

The following hardware is used to operate VCADS Pro. The tools can be ordered from Volvo quoting the specied part number. VCADS Pro tools for diagnostics is for vehicles built from 1998 and later. For diagnostics on vehicles built prior to 1998, use Pro-Link 9000 (J-38500) with Volvo Application Cartridge J-385002000.
W2003597
See list on next page for information about the tools in the picture.
35
Group 28
Tools
1 2 3 9998574 9998555 9812331 J-43999 J-43939 9998496 9998489 9998554 9998553 9998617
PC tool -package. Didgipass password generator, model 300 or 500. Laser printer; HP 1100A (To be purchased from a local supplier. Not supplied by Volvo.) Laser printer labels. Used when printing labels for the engine electronic control unit (EECU). Communication interface unit; for connection between the PC tool and the vehicles diagnostic connector. Extension Cable; for communication, 22 yards (optional) 6 Pin Diagnostic adapter; for vehicles prior to 1999 9 Pin Diagnostic adapter; for vehicles built from January 1999. Pressure Guage Oscilloscope interface Oscilloscope Cable-BNC connector cable to banana jack (optional) Oscilloscope Cable-25 pin parallel cable (optional) Programming Kit (see below)
9808635
9808560
Programming Unit
Cable for direct connection to the Engine ECU Cable for direct connection to the Vehicle ECU Cable for direct connection to the Intstrument Cluster Cable for power supply
9808561 9808562 9808563
Note: There are three ways of connecting the power cable; 1) To radio power supply, 2) Directly to battery with battery. 3) To cigar lighter.
36
Group 28
Design and Function
Design and Function

Vehicle Management System Strategy
The vehicle management system is designed to incorporate the entire vehicle system and instantly receive real-time data from key vehicle components. Vehicle Communication Equipment Transmission SRS Brakes Engine Instrument Cluster
Uniform interfaces between the control systems. Standard adaptations to the vehicles functions. Stand-alone diagnostics for the vehicles main electronic components.
Production
Owner
Driver
Body Builder
Expansion capability
Service
Conventional Control Systems

In principle, a conventional control system is constructed so that one or several of the vehicles components have their own control units that receive signals from different sensors. Each control unit serves its own component and sends signals to other control units via electrical wires. An example of this is the engine control unit that receives signals from different sensors on the engine, as well as from other control units on the vehicle. The accelerator pedal position, the clutch pedal position, the speed signal, engaged power take-off etc., are sent to the engine electronic control unit (EECU) via wires from different sensors and contacts. The system must have one or more communication ports, to which tools can be connected for programming as well as for reading information and any fault codes. In the future, the vehicles sub-components will require several specic control units and the vehicle electronics will therefore become even more complex. In the long run this will limit the ability of conventional control systems to fulll their tasks.
T3008752
37
Group 28
Design and Function
Data Link System

Volvos vehicle electronics are constructed on the principle that all communications between the control units in the system are accomplished via two data links:
the J1939 Control Data Link and the J1587/1708 Information Data Link
The vehicles main components have their own control units that are connected to one or both links in order to be able to communicate with each other. Here is how the system works on a vehicle equipped with a Volvo engine: when the driver wants to increase the vehicles speed, a signal is sent from the accelerator position sensor to the vehicle electronic control unit (VECU). The signal is then transferred via the data link to the engine electronic control unit (EECU). The EECU communicates with its own sensors to verify that the conditions exist to permit increased acceleration. If the conditions are met, it carries out the VECUs request. The EECU communicates with the other control units via the data links, either by requesting or by receiving direct information that all prerequisites are met in order to be able to carry out the request. If an error should occur in any of the systems, a signal is sent out on the J1587/1708 information data link, which makes it possible to read the information, either on the drivers instrument cluster, or via a PC or diagnostic tool (i.e. Pro-Link, VCADS or VCADS Pro) connected to the diagnostic connector. The data link system provides an extremely exible solution with great potential for expansion.
B
J1587 /1708 J1939
CAUTION
No modications or connections should be made to wires 406 (yellow), 407 (green) or 408 (shielded). These wires carry the high-speed communications between the electronic systems in the vehicle. Any modication, connection to, or damage to these wires can result in the failure of the vehicles electronic systems.
38
Group 28
Design and Function
Data Links, Design and Function

Data links are one way of transferring information between various components. In conventional systems, analog signals have mostly been used. Analog signals mean that different voltage levels represent different values. A simplied example of analog signals could be: 1 volt = 10 C 2 volts = 20 C 3 volts = 30 C
W3003960

Data links use digital communication. This means that the voltage only varies between two different values, either high or low. By combining these high and low signals various values can be described. The diagram shows an oscilloscope image where the voltage of the data link is measured. As can be seen from the diagram, a large part of the time the link is silent but at times a number of fast pulses are sent. A group of pulses is called a message. The enlarged portion of the diagram shows that each message consists of a combination of high and low voltage levels. The following sections describe what type of information this message contains.
W3003957
39
Group 28
Design and Function
Messages and Information Content

Different voltage levels are represented by the different numbers in the binary number system. The binary number system has only two numbers, one and zero. The ones are normally represented by a high voltage and the zeros by a low voltage. Each binary number is called a bit. This message consists of four groups of binary numbers. Each group of eight bits makes up a byte, a decimal number from 0 255 with information, as well as a start bit and a stop bit. The purpose of the start and stop bits is to function as markers for where that group of data begins and ends. In the diagram above only the start and stop bits are labeled. The other information is shaded.
W3003956
Example
The diagram shows the information content in the four different parts of the message. The start and stop bits are shaded since they do not contain any information. The box in the diagram shows the different binary and decimal values which comprise the message. Note: The information is sent over the data link with the least bit rst in the binary numbers. The normal way to notate binary numbers is shown in the box in the diagram.
W3003958
40
Group 28
Design and Function
W2003293
Message 144091000240 in this example, has the following meaning: A B C MID 144 The message comes from the Vehicle ECU. PID 091 The message states the accelerator pedal position percentage. Data 000 The accelerator pedal is in the completely released position. 000 is a data component, which in this case states how much the accelerator pedal has been pressed down. The value can vary between 000 for a completely released pedal and 255 for a completely pressed down accelerator pedal. D Check 240 The checksum is used as a check that the message is reasonable.
41
Group 28
Design and Function
Diagnostic Message Description

The Society of Automotive Engineers (SAE) and the American Trucking Association (ATA) have developed a standardized list of diagnostic messages, or fault codes. These diagnostic messages are used to communicate information about problems detected by an electronic control units (ECUs) self-diagnostic program. In addition to the industry-standard SAE codes, Volvo has developed a list of diagnostic messages that are unique to Volvo applications. Generally, diagnostic messages and their descriptions are listed in the service manual for each respective ECU and in the user manual for diagnostic tools. MID PID MID is an acronym for Message Identication Description. MIDs are SAE standardized codes used to identify individual electronic control units. PID is an acronym for Parameter Identication Description. PIDs are SAE standardized codes used to identify parameters or values.
PPID PPID is an acronym for Proprietary Parameter Identication Description. PPIDs are Volvos unique codes used to identify parameters or values. SID SID is an acronym for Subsystem Identication Description. SIDs are SAE standardized codes used to identify components.
PSID PSID is an acronym for Proprietary Subsystem Identication Description. PSIDs are Volvos unique codes used to identify components. FMI FMI is an acronym for Failure Mode Identier. FMIs are SAE standardized codes used to identify a type of failure.
42
Group 28
Design and Function
Data Link Communication

General
Communication between the different ECUs takes place via the two data links: the J1939 control data link and the J1587/1708 information data link. The diagram shows how the control units, the diagnostic connector, and the instrument cluster are connected in principle. The instrument cluster, the engine ECU and the diagnostic connector are always included in the system. The system may include other control units, depending on the vehicle type, engine type and optional equipment. Instrument Cluster MIDs 234 & 140 Communication Equipment (Expansion capability)
SRS ECU MID 232
Engine ECU MID 128

Diagnostic connector
Terminating Resistor
Vehicle ECU MID 144

SAE J1587 /1708
SAE J1939
Transmission ECU MID 130
Control unit (Expansion capability) ABS ECU MID 136

43
Group 28
Design and Function
SAE J1939 Control Data Link

The systems control signals are sent via this link. The J1939 link is very fast, operating at 250,000 bits per second. This operating speed allows the system to function more effectively and adapt quickly to changing conditions and vehicle requirements. The link complies with SAE standards, and consists of three twisted wires: a green wire (407), a yellow wire (406) and in early deisgns a shield wire (408optional). The twisted wire set (40 turns per meter) is used to protect the link from electrical interference.
CAUTION
No modications or connections should be made to wires 406 (yellow), 407 (green) or 408 (shielded). These wires carry the high-speed communications between the electronic systems in the vehicle. Any modication, connection to, or damage to these wires can result in the failure of the vehicles electronic systems.
44
Group 28
Design and Function
Communication Equipment (Expansion capability)
W3002905
Instrument Cluster MIDs 234 & 140
Terminating resistors are wired into each end of the J1939 data link. One is located near the ABS ECU and the other near the engine ECU. On Volvo engines, the terminating resistor at the engine ECU end is located inside the EECU. If you measure 120 ohm (+/- 10 ohm) between circuits 406 and 407, then there is only one terminatig resistor. Check to determine which is missing and reconnect it. Note: within of the within fault. With Volvo engines, one terminating resistor is the engine ECU. The other is poitioned at the end J1939 network, typically at the ABS ECU. The one the ECU is not accessible and should not be at
SRS ECU MID 232
Engine ECU MID 128

If you measure less than 60 ohm, only two terminating resistors are used in a vehicle. Never install three in one truck. If more than two terminating resistors exist in the J1939 circuit, damage to the ECU electronics can occur over time. You can easily check to see if you have two resistors by measuring the resistance between circuits 406 and 407 with the ignition OFF. The correct resistance is 60
. The purpose of these resistors is to prevent data link signal reections. They must remain connected for the system to function properly.
Vehicle ECU MID 144

SAE J1587 /1708
SAE J1939

45
Group 28
Design and Function
SAE J1587/1708 Information Data Link

Information and diagnostic signals are sent via this link. The link also functions as a backup should the J1939 control data link fail to function for any reason. SAE J1708 is a standard that species hardware and a databus speed of 9600 bits per second. SAE J1587 is a protocol that provides a standard method for exchanging information between microprocessors. The J1587 link consists of two wires (400 and 401) that are twisted around each other approx. 30 turns per meter. The twisted-pair wires are to protect the link against electrical interference.
SRS ECU MID 232
CAUTION
If a circuit must be added to the electrical system, and will carry high currents or frequencies, route it in a location AWAY from wires 400 and 401 to prevent mutual inductance from interfering with data link functions. Engine ECU MID 128
Diagnostic connector Terminating Resistor
Vehicle ECU MID 144
CAUTION
Wires 400 and 401 MUST NOT be cut or spliced for any connections. These wires are used for the transmission of data for diagnostic messages and gauges. Modifying this circuit can cause these functions to fail.
SAE J1587 /1708 SAE J1939
SAE J1922 Data Link

For a short period of time some vehicles were produced which used the J1922 data link. The J1922 data link was developed as an interim standard until the J1939 control data link was established. The J1922 link operates on J1708 dened hardware and is used like a control link for communication between engine, transmission and ABS ECUs. The J1922 link consists of two wires (404 and 405) that are twisted around each other approx. 30 turns per meter. The twisted-pair wires are to protect the link against electrical interference.

46
Group 28
Design and Function
Diagnostic Connector
SRS ECU MID 232
Engine ECU MID 128

W8001310
The diagnostic connector is a round Deutsch connector located in the drivers side kick panel. The diagnostic connector is connected to the J1587/1708 information link and gives the system a way to communicate with an external PC or diagnostic tool. With a PC or diagnostic tool connected, fault codes can be read from all the control units. This is important in fault tracing to carry out basic checks of all the vital parts of the vehicles electronics. Some programming can also be done via the diagnostic connector. The standard diagnostic connector is a 6pin Deutsch. A newer 9pin Deutsch version has been introduced on certain vehicle/engine variants. The new 9pin connector connects to both the J1939 and J1587/1708 data links.
Vehicle ECU MID 144

SAE J1587 /1708
SAE J1939

47
Group 28
Design and Function
Communication Equipment
SRS ECU MID 232

W2003295
Pro-Driver Display
Various manufacturers offer communication equipment designed to allow drivers to keep log book records electronically, maintain communication with the home ofce, monitor and record vehicle operations, and many other functions. Currently these communication devices are connected to the J1587/1708 Information Data Link. Newer and more sophisticated versions of these devices may also connect to the J1939 Control Data Link. Note: No provisions have currently been made to add communication equipment to the J1939 link in aftermarket adaptations.
Engine ECU MID 128

Vehicle ECU MID 144

SAE J1587 /1708
SAE J1939
CAUTION
No modications or connections should be made to wires 406 (yellow), 407 (green) or 408 (shielded). These wires carry the high-speed communications between the electronic systems in the vehicle. Any modication, connection to, or damage to these wires can result in the failure of the vehicles electronic systems. Control unit (Expansion capability) ABS ECU MID 136
Provisions are made for adding aftermarket communication devices to the J1587/1708 link via connectors in the wiring harness. Some of the communication devices currently used in Volvo trucks include Road Relay, Pro-Driver, Qualcomm and Highway Master.
48
Group 28
Design and Function
Instrument Cluster
W3003621
The instrument cluster used on Volvo vehicles uses both data link signals and hardwired sensors depending on the vehicle/engine variant and instrument conguration. A graphic display screen is integrated into the instrument cluster to provide additional features and vehicle system information not available from other gauges. Diagnostic codes can also be retrieved and displayed. The instrument cluster is connected to the J1587/1708 information data link. For information about the instrumentation that communicates via the data link, refer to service manuals in group 38: Model: WG/AC/WC/WI from 1994; WX with electronic engines from 5.96 WX VN from 1.982.99 VN from 3.99 ADN VHD See Publication: Data Link Instrumentation, PV776381620SM
SRS ECU MID 232
Kysor Mini-Cluster, PV776 TSP108262 Instrumentation, PV776 TSP106805/1 Instrumentation, PV776 TSP139790
Engine ECU MID 128

Vehicle ECU MID 144

SAE J1587 /1708
SAE J1939

49
Group 28
Design and Function
Vehicle Electronic Control Unit (VECU)
W2002673
The vehicle electronic control unit (VECU) is part of the integrated vehicle electronics. The VECU is located in the cab, but its specic mounting location varies by model. The main function of the VECU is to collect data from different cab control units and then to pass this data to other ECUs in the system (primarily to the engine ECU). For detailed information about the VECU see Vehicle Electronic Control Unit, MID 144, Volvo service publication number PV776300610. The VECU is only used in vehicles equipped with Volvo engines.
SRS ECU MID 232
Engine ECU MID 128

Vehicle ECU MID 144

SAE J1587 /1708
SAE J1939

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Design and Function
Engine Electronic Control Unit
W2003294
Irrespective of engine variant, the engine electronic control unit (EECU) performs the same basic functions in the system: control of engine operation. The EECU receives signals from various sensors and the data links. Based on these signals and the parameters programmed into the EECU, the EECU calculates the proper injection angle and fuel quantity to satisfy the requested operating requirements. The EECU is connected to both the J1939 control data link and the J1587/1708 information data link. Note: Early production model EECUs may use only the J1587/1708 data link, or the J1587/1708 and the J1922 data links. For detailed information about EECUs see the service literature for that particular engine.
SRS ECU MID 232
Engine ECU MID 128

Vehicle ECU MID 144

SAE J1587 /1708
SAE J1939

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Design and Function
EECU
The EECU is an electronic control unit that monitors certain operational parameters of the Volvo engine from the SAE J1587 Data Link and appropriate sensors.
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Design and Function
ON/OFF Engine Cooling Fan

The EECU receives the input from the engine coolant temperature sensor to turn on the cooling fan at 115 C (202 F). The fan will remain engaged until the engine coolant drops to 90 C (195 F). The ON/OFF cooling fan can also be engaged by the EECU if it receives a signal from the air conditioning systems APADS module. When the A/C system pressure reaches 20.5 bar (300 psi) the APADS module will send a signal to the EECU to engage the cooling fan. The on time of the cooling fan is controlled by the APADS module. If the EECU does not receive any coolant temperature data, the fan is engaged for a minimum of 30 seconds. The fan will stay engaged until valid coolant temperature data is received and the coolant temperature drops be low 90 C (195 F).
Converting Engine Oil Pressure Signal

The EECU takes an analog signal from a pressure transducer and broadcasts the signal on the SAE J1587 data link.
Engine Information and Warning Lamp-On Dash
Engine Oil Pressure The EECU will make the STOP lamp light and the icon in the display light up if the oil pressure is < 41 3 kPa (6 1.2 psi). Also a warning signal sounds if the engine is running. Engine Coolant Level STOP lamp light stay on The EECU will make the (solid) if the low coolant level sensor detects a low coolant level condition. The low coolant level condition is active only after 5 seconds of a constant signal from the low level sensor. Engine Coolant Temperature The EECU will make the STOP lamp light illuminate and gauge LED illuminate, plus the icon in the display if a high coolant temperature from the engine ECU is received. Engine Oil Temperature If the Engine oil temperature becomes too high an information message is shown automatically with the text HIGH. At the same time the yellow INFO lamp under the display lights up. The engine may also derate, if it is set up to do so in the engine ECU programming. The temperature which activates this warning varies for different engines. This temperature is set in the engine ECU. For Volvo en gines, it is 275 F (135 C).
Note: If the engine is running and the stop lamp comes on you will get a buzzer or warning signal.
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Design and Function
Electronic Unit Injectors

The engine has six unit injectors, one for each cylinder. Each Electronic Unit Injector, or EUI, is a combination of injection pump and injector, but operates at a considerably higher pressure than a standard injector. Each unit injector is mounted vertically in the cylinder head at each cylinder, centered between the four valves. The compressive force for the unit injector is developed by a lobe on the overhead camshaft. It is then transferred by a rocker arm to the injector. The injection angle and the amount of fuel to be injected into the cylinder is determined by the EECU, which transmits signals to the electromagnetically controlled fuel valve in the unit injector valve housing.
Make sure to turn the ignition key off before working on the electronic unit injectors. This eliminates the possibility of electric shock which may result in personal injury or death.
T2006998
Electronic unit injector
Calculating Fuel Quantities

The EECU calculates the quantity of fuel to be injected into a cylinder. This calculation provides the period of time during which the fuel valve is closed (when the fuel valve is closed, fuel is injected into the cylinder). Factors that determine how much fuel to inject into a cylinder are:
Requested fuel amount Limitation of fuel amount
Flywheel
There are 54 notches cut into the ywheel; these are read by the speed sensor for the ywheel. With the help of these notches, the EECU can set the correct injection angle and calculate the time which gives the correct fuel amount. The notches are divided into three groups, with 18 notches in each group. There is a at area between each group of notches equivalent to 18 . A at area and 18 notches is equivalent to 120 on the ywheel, or a third of a full turn. The area between each notch equals 6 on the ywheel.
T2007019
Flywheel
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Design and Function
Cam Sensor Wheel

The cam sensor wheel has six teeth (one tooth for each unit injector) evenly spaced at 60 center-to-center, plus an extra tooth, placed 15 before the tooth that indicates cylinder number 1. The EECU uses these teeth to determine which injector is in line for injection. In other words, each tooth (teeth 16) represents the start of a cylinder operating phase (does not apply to the extra tooth).
T2007099
Cam sensor wheel
Flywheel and Cam Sensor Wheel

The ratio between the ywheel and cam sensor is 2:1. This means that when the ywheel has rotated two turns, the cam sensor wheel has rotated one turn or when the ywheel has rotated 30 , the cam sensor wheel has rotated 15 and so on.
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Design and Function
Injector Operational Phases

The operational phase of the number 1 cylinder is given in the following example. Fuel is injected at 7 before top dead center (BTDC) (the injection angle may vary be tween 18 BTDC and 6 after top dead center). The cam sensor reacts to the extra tooth on the cam sensor wheel. This informs the control unit that the next tooth in turn (tooth 1) indicates the number 1 cylinder.
T2007100
Locating number 1 cylinder A top dead center (TDC)
The cam sensor wheel detects tooth 1 and the ywheel sensor reaches a at area on the ywheel at the same time. At this point, the piston is on its way upward in the cylinder and no fuel is injected into the cylinder.
T2007101
Engine speed calculated A top dead center (TDC)
The sensor detects the rst notch after a at area on the ywheel. Using the engine speed calculation, the EECU can determine:
When to begin injecting fuel into the number 1 cylin der. This gives selected injection angle (7 BTDC in the example). When to stop injecting fuel into the number 1 cylinder. This gives the selected fuel amount.
T2007102
Calculating injection angle A B C TDC 7 BTDC (injection begins) ATDC (injection stops)

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Design and Function
From the rst notch after a at area, the EECU advances the angle from which it is to begin injecting fuel into the cylinder and on to the angle where it is to stop injecting fuel into the cylinder. If the calculated angles do not agree with the notches on the ywheel, the EECU measures the time between the last notches to rectify the angles. Because the EECU must calculate the engine speed during 120 , the engine speed calculation for each cylinder occurs one step ahead at all times. In other words, during the operational phase for one cylinder, the EECU calculates engine speed for the next cylinder and so on. This procedure is repeated for the next cylinder in the same manner as described for the number 1 cylinder. Note: Note that the calculation of the injection angle and fuel amount takes place continuously, regardless of the operational phase of the cylinders.
Cylinder Balancing
The EECU can provide each cylinder with a different quantity of fuel to make the engine run more smoothly at idling speeds. At higher speeds, there are no problems with smooth running and all cylinders receive the same amount of fuel. If the variation in fuel quantity between different cylinders is too great during cylinder balancing, the EUI, which deviates most, triggers a fault code from 31 to 36. This indicates that there must be a fault in the cylinder in question. For cylinder balancing to take place, the following conditions must be satised:
Idling speed must be below 650 rpm. Fuel requirement must be below a specic rating. Idling adjustment function must not be active. PTO not active. Cruise control mode not active. Accelerator pedal in idling position. Coolant temperature must be above 50 C (122 F). Vehicle must be at a standstill. No fault codes in existence.
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Design and Function
Other Functions
The EECU guides the EUIs based on the following control functions. Smoke limitation To prevent injecting too much fuel into the cylinder, the EECU checks:
Boost pressure Engine speed Boost air temperature
PTO engine speed The engine can be kept at a constant rpm level that is at least 100 rpm greater than low idle and less than high idle. Cruise control The engine can be set to maintain a constant speed between 48 km/h (30 mph) and 140 km/h (87 mph). For the cruise control mode to function, the following conditions must be satised:
Cruise control in ON position. Brake pedal must not be depressed. Clutch pedal must not be depressed.
Speed limitation The EECU can be programmed to limit the maximum speed up to 140 km/h (87 mph). A fault on the sensor signal and/or a faulty cable to the EECU generates a fault code. Differentiated speed limitation This mode is available as an option. It limits the speed to various levels depending on the gear selected. In other words, each gear has a maximum speed.
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Design and Function
Engine protection To a certain extent, the EECU can also protect the engine by:
Reducing engine speed at low coolant temperatures (cold engine cranking): When coolant temperature is lower than 50 C (122 F), engine speed is limited during a specic time to 1000 rpm immediately after starting. At 20 C (4 F) and lower, this period is 16 seconds, and above 50 C (122 F) the period is 0 second. This function allows oil pressure to build up before engine speeds become too high.
W2000768
Engine speed during cold cranking
Reducing engine output at high coolant temperatures (during engine operation): Should coolant temperature exceed 102 C (216 F), the maximum fuel provision is reduced by a certain percentage of its original rating and the coolant temperature warning lamp lights up. If the coolant temperature becomes excessively high, the engine will gradually reduce power to 50%. When coolant temperature has dropped below 100 C (212 F), maximum fuel provision is permitted again and the coolant temperature warning lamp goes out.
W2000769
Engine speed during operation
The safety signal is an optional system that enables the EECU too switch off the engine. The EECU can be programmed to provide three levels of engine protection:
No engine protection (re engine) Engine protection Extended engine protection
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Design and Function
Idle shutdown This function is available as an option. It switches off the engine after it has run at idling speed for a specic time. This time can be set to between 1 and 40 minutes. The engine will be switched off if the following conditions are met:
Vehicle speed is 0. Parking brake is applied. Engine running at idle speed. Coolant temperature is above 45 C (113 F).

Cold starts, idling Idling speed is automatically boosted to heat the engine more quickly from a cold start when coolant temperature is below a specic level. When this mode is activated, idling speed is boosted to 650 rpm. When coolant temperature has reached 30 C (86 F), idling speed drops steadily to its normal level which is reached at a coolant temperature of 45 C (113 F).
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Design and Function
Starting the engine Before any fuel can be injected into the cylinders, the EECU must have had a sufcient amount of time to carry out the rst calculations on injection angles and fuel quantities. This time is equivalent to two engine revolutions. VEB (VOLVO engine brake) The VEB consists of an exhaust brake and a compression brake. The EECU activates the VEB when the following conditions are satised:
Accelerator pedal at idling position (fuel injection must not occur). Engine speed must exceed 1200 rpm. Clutch pedal must not be depressed. Boost pressure must be lower than 152 kPa (22 psi) (overpressure). PTO not activated. Vehicle speed is greater than 3.2 km/h (2 mph). ABS not activated. Engine coolant temperature is greater than 40 2 C (104 5 F). Engine oil temperature is greater then 55 C (130 F).

The VEB may be activated when the cruise control is in use. For this to take place, the following condition must be satised:
Vehicle road speed must exceed the set speed of the cruise control by between 5 and 30 km/h (4 and 20 mph), depending on what level has been programmed into the EECU.
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Design and Function
Idle Speed Adjustment

Note: This service information should be considered supplemental to the Engine Control information for base D12 B and C engine. The idle speed is adjusted on the VN vehicles at the turn signal stalk. The idle speed can be adjusted between 500 RPM and 650 RPM. Prerequisites to adjusting idle speed:

1 2 3
Accelerator pedal not depressed. Engine temperature above 45 C (113 F). Vehicle is stationary / Parking brake set.
Idle speed adjustment Cruise control in the ON position. Depress the brake pedal and continue to hold it during the entire adjustment procedure. Move the ON/OFF switch to the RESUME position and hold for four seconds. Release the switch; the engine speed will drop to approximately 500 RPM. The idle speed can be adjusted with the SET switch. Each time the SET switch is pressed, the idle speed will increase approximately 10 RPM. Move the ON/OFF switch to the RESUME position and the idle speed will decrease approximately 10 RPM each time. Hold in the SET switch and move the ON/OFF switch to the RESUME position and hold them in position for four seconds. Release the switches Release the brake pedal and the new idle speed is set. If an error was made during the adjustment procedure, the default idle speed will be maintained.
T3014326
1 2
A-Set B-Resume, On/Off
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Design and Function
ABS Brake System ECU
W5000669
The ABS ECU continuously monitors wheel speed and helps to control braking in exterme situations. It also helps prevent wheel spin in vehicles equipped with traction control systems (ATC or TCS). The ABS ECU is connected to the J1939 control data link and the J1587/1708 information data link. Note: Early production model ABS ECUs may be connected to the J1587/1708 and J1922 data link or have no data link connection at all. For detailed information about ABS systems see the appropriate service literature for the type of ABS system used on the vehicle.
SRS ECU MID 232
Engine ECU MID 128

Vehicle ECU MID 144

SAE J1587 /1708
SAE J1939

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Design and Function
SRS Airbag ECU
T8006850
The Supplemental Restraint System (SRS) ECU senses frontal collisions with two rapid deceleration sensors. The SRS ECU will deploy the airbag module in the steering wheel if a collision of sufcient force and duration is detected. The SRS ECU is connected to the J1587/1708 information data link. For detailed information about the SRS see Supplemental Restraint System (SRS), VNL, VNM, Volvo service publication number PV776TSP21771/1. Note: The SRS system is not available on all models.
SRS ECU MID 232
Engine ECU MID 128

Vehicle ECU MID 144

SAE J1587 /1708
SAE J1939

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Design and Function
Transmission ECU
W4001493
The transmission electronic control unit (ECU) receives signals directly from switches and sensors and via the data links. Based on those inputs, the transmission ECU controls transmission operation via solenoid valves and switches. The transmission ECU also supplies system status and diagnostic information. The transmission ECU is connected to both the J1939 control data link and the J1587/1708 information data link. Note: Early production model transmission ECUs may be connected to the J1587/1708 and J1922 data links. For detailed information about transmission ECUs see the service literature for that particular transmission.
SRS ECU MID 232
Engine ECU MID 128

Vehicle ECU MID 144

SAE J1587 /1708
SAE J1939

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Design and Function
Breakout Boxes and Harnesses

The harness adapters are used to gain access to the EECU, the VECU, the throttle pedal and certain other sensors on the engine, while the circuit is intact. This allows the technician and vehicle to take measurements on functional circuits. Example: The 36-pin breakout box allows the technician to measure resistance and voltage on the EECUs EA connector (which covers the engine mounted components) and the EB connector (which covers the remaining components involved).
CAUTION
Check that the proper cable and connector location is observed and used while connectin to the ECU. Ohterwise, damage to the ECU or tool will occur.
W2002712
W2002710
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Design and Function
VECU Overview
The Vehicle Electronic Control Unit (VECU) receives inputs and generates output signals for functions associated with cab devices. It also converts information into digital data to be broadcast over the J1587/1708 Information Link and the J1939 Control Link. Note: The VECU may also be referred to as the Cab Controller on the graphics display of the VN series dash and in some Volvo publications.
VECU Programming
Each VECU is programmed with specic vehicle performance characteristics corresponding to customerordered options for that particular vehicle. This dataset is stored in the VECU memory, making the VECU unique to each vehicle. For this reason, it is not possible to swap a suspected faulty VECU with one from another vehicle without reprogramming the replacement VECU. Replacement VECUs are programmed using the VCADS Pro tool. Programming is based on the particular dataset that matches the vehicle; datasets are stored in the Volvo Data Administration (VDA) database. Authorized technicians can update and/or alter software datasets, change customer parameters, and perform campaigns. For more information about the proper operation of the VCADS Pro tool and VECU programming, please refer to Information on VCADS Pro in Group O. This manual is also available as a pdf le within VCADS Pro tool located under Help. Note: Customer parameter changes are not stored in the VDA database. Therefore, after a replacement VECU is programmed for the vehicle, it will have to be customized to include those customer alterations.
W0001632
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Design and Function
VECU Functions
The following functions are monitored or controlled by the VECU. Only the functions needed for each specic vehicle/engine application are wired and programmed into the VECU.
Accelerator Pedal
The accelerator pedal signals travel rst to the VECU and are transferred to the Engine Electronic Control Unit (EECU) via the J1939 Control Link. If there is a fault in the J1939 Control Link, the accelerator pedal signal travels to the EECU via the J587/1708 Information Link. The vehicle can also be driven in the limp home mode is there is a fault in both links. In this situation, the idle validation switch is used to determine when the accelerator pedal is pressed; then, the VECU sends a buffered idle validation switch signal (via hard wire) to the EECU.
Second Accelerator Pedal

If the vehicle is equipped with a second accelerator pedal, the second accelerator pedal signals travel rst to the VECU and are transferred to the Engine Electronic Control Unit (EECU) via the J1939 Control Link. A road speed limit may be programmed into the VECU to limit vehicle speed when the second accelerator pedal is being used. Second accelerator pedal road speed limit can be programmed using the VCADS Pro tool.
Speedometer
The speed signal comes from a sensor on the transmission or as a digital signal, if an electronically-controlled transmission (Allison) is used. The VECU then sends the vehicle speed signal on both the J1939 Control Link and J1587/1708 Information Link. The signal on the J1939 Control Link is used to control vehicle operation. The signal on the J1587/1708 Information Link is collected by the instrument cluster and is displayed on the speedometer.
Cruise Control
The VECU receives signals from the cruise control switch and sends signals to the EECU via the J1939 Control Link. Cruise control parameters can be programmed with the VCADS Pro too.
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Design and Function
Power Take-Off (PTO)

PTO functions are controlled by the VECU through the cruise control switch. Basic or optional PTO parameters can be programmed with the VCADS Pro tool.
Ignition Switch
Ignition switch positions are recognized by the VECU, which transfers the ignition switch position information to the EECU.
Idle Shut-Down
Timed engine shut-off can be controlled by the VECU as a customer option. Idle shut-down time can be programmed with the VCADS Pro tool.
Engine Brake
The control for the engine brake (including the exhaust pressure governor [EPG] and compression brake [VCB], if installed) are monitored by the VECU. At the request of the ABS ECU, the VECU can de-activate the engine brake.
Windshield Wipers
Windshield wiper function on the VN and VHD (with Volvo engine) is controlled by the VECU using signals received from the wiper switch.
Calibration Number
The calibration number (K factor) is a measurement of Drivetrain Constant Pulses per Mile and is used by the VECU to determine vehicle speed and distance traveled. The calibration number is calculated by multiplying tire revolutions per mile x rear axle ratio x number of teeth on the transmission output shaft chopper wheel. The calibration number is programmed into the VECU using the VCADS Pro tool.
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Design and Function
Optional Engine Speed Limit

Optional engine speed limit is the maximum speed at which the engine can be operated with the vehicle at zero road speed and the PTO mode engaged. Optional engine speed limit parameters can be programmed with the VCADS Pro tool.
Optional Vehicle Speed Limit

Optional vehicle speed limit allows for an optional switch to limit vehicle speed. Typically, this switch is operated on the vehicle by someone other than the driver, such as a garbage collector who rides on the back of the vehicle. Optional vehicle speed limit parameters can be programmed with the VCADS Pro tool. Note: Basic vehicle speed limit is set by the EECU.
Shut-Down Request
Optional engine shut-down request is made via a remote mounted switch (the ignition switch is the basic engine shut-down request). After the VECU receives the shutdown request, the request is sent to the EECU via the J1939 Control Link. Shut-down request is enabled using the VCADS Pro tool. Note: The engine shut-down request function should not be considered or used as an emergency shut-down.
Torque Limit
Torque limit 1 and 2 are used to limit drive line torque. Torque limit parameters can be programmed with the VCADS Pro tool.
Engine Fan Request

The VECU receives the request for engine fan operation from either a manual switch or a high pressure A/C refrigerant switch. The VECU then transfers the request to the EECU via the J1939 Control Link.
Brake/Clutch Status Switches

The VECU recognizes the position of the brake, clutch, and parking brake. Various VECU functions (i.e. cruise control or PTO) operate only when these switches are in the proper position.
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Design and Function
Safety Warnings/Cautions Always wear approved eye protection. To avoid personal injury and damage to the vehicle,
always refer to and follow the vehicle manufacturers WARNINGS, CAUTIONS, and service procedures. Unless otherwise directed, turn the ignition switch OFF before disconnecting or connecting any electrical components. Read and understand the manual provided with the tool before operating your Pro-Link 9000. VGHT recommends an assistant drive the vehicle while you use the Pro-Link 9000. Never leave the vehicle unattended while testing.
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Design and Function
VCADS Pro
From the VCADS Pro Main Menu, VCADS Pro Test, Calibration, Programming and Job Cards are started. In addition, a number of settings can be done, i.e. the selection of language. Ensure your language is selected to get the right tests for your countrys vehicle variant. Do one of the following to start an application:
Select the application in the menu Select application. When highlighted press Enter. Click the programs function button in the toolbar; test (1), calibration (2), programming (3) and job card (4).
T0009469
Double click the desired program in the function tree.
The following can be performed in the Administrative functions
Language selection Selection of screen saver and screen saver delay. Selection of background image. Selection of default application. Update the system. Get a new program version of VCADS Pro from Volvo via connection to the central systems. User administration. Select the user to change the password for. This function requires authorization and is not available to all users. General adminstration. Selection of communication method, vehicle/machine type and activation/deactivation of the simulator is possible.
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Design and Function
Sensor Locations
VN/VHD Sensors and Switches
W2003551
Inside cab 1 2 3 4 5 6 7 8 Throttle position sensor Microswitch(service brake) Engine/Exhaust Brake VECU Pressure Switch-Parking and Service Brake ON/OFFResume Switch Resume Switch Diagnostic connector
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Design and Function
D7C
1 2 3 4 5 6 EECU connector EA/EB EPG solenoid Boost pressure/temperature sensor Oil pressure/temperature sensor Engine timing (crank) sensor Engine electronic control unit (EECU)
W2002748
1 2 3
Needle lift sensor (at injector #1) Coolant temperature sensor Redundant engine speed sensor (1); Fuel pressure/temperature sensor (2); Fuel shut-off valve (3); 7pin connector (4), includes rack drive, rack position sensor, and timing sleeve
W2002749
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Design and Function
D12B
1 2 3 4 5 6 7 Boost pressure/temperature sensor Coolant temperature sensor Oil pressure/temperature sensor Engine timing (crank) sensor Engine electronic control unit (EECU) EECU connector EA/EB Engine position (cam) sensor
W2002745
1 2
Compression brake, VCB (under valve cover) EPG control (PWM box)
W2002746
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Design and Function
D12C
W2003550
Fig. 10: Engine electronic control unit (EECU) sensor locations D12C Several engine sensors send signals to the EECU. They are: 1 Cam Sensor (timing gears)This sensor determines which cylinder is in line for injection. It detects the camshafts position via a pole wheel bolted to the camshaft drive gear. Oil Pressure/temperature sensor (cylinder block)This combined sensor monitors oil pressure and oil temperature. Fuel Pressure/Temperature Sensor Monitors the fuel pressure and fuel temperature 4 Crank Sensor (ywheel housing) This sensor detects the crank-shaftss position and speed, via teeth in the ywheel. Detects Engine RPMs. Coolant Temperature Sensor (cylinder head) This sensor monitors coolant temperature. Intake Manifold Pressure (intake manifold)This is a combined sensor that monitors both the intake manifold air pressure and temperature.
5 6
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Design and Function
Control Unit Locations

VN/VHD: Cab and Engine Compartment
The diagram shows the normal location of the different control units on a VN vehicle equipped with a Volvo engine. Control units may vary slightly in location, depending on vehicle and component type (variant). The locations are virtually the same on a VHD vehicle.
W3003955
1 2 3
Vehicle electronic control unit (VECU) Instrument cluster ABS control unit; crossmember located toward rear of cab
4 5
SRS control unit Engine electronic control unit (EECU)
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Design and Function
WG/AC: Cab and Engine Compartment

The diagram shows the normal location of the different control units on WG and AC vehicles. Control units may vary slightly in location, depending on vehicle type (variant).
W3003963
1 2
ABS control unit, on right side frame rail Instrument cluster
3 4
Vehicle electronic control unit (VECU) Engine electronic control unit (EECU)
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Design and Function
WX/WXLL: Cab and Engine Compartment

The diagram shows the normal location of the different control units on a WX or WXLL vehicle. Control units may vary slightly in location, depending on vehicle type (variant).
W3003961
1 2 3 4
Vehicle electronic control unit (VECU), location in WX narrow cab only Instrument cluster Engine electronic control unit (EECU) Transmission ECU, under drivers seat
5 6 7
ABS control unit, right side engine tunnel VECU, WX and WXLL, right side engine tunnel ABS control unit, location in WX narrow cab only
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Design and Function
WXR: Cab and Engine Compartment

The diagram shows the normal location of the different control units on a WXR vehicle. Control units may vary slightly in location, depending on vehicle type (variant).
W3003962
1 2 3
Engine electronic control unit (EECU) Instrument cluster ABS control unit
4 5
Transmission ECU Vehicle electronic control unit (VECU) on left side of cab, below center dash panel
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Design and Function
Fuses and Relays
W8000923
The VN/VHD vehicles have easy access to the TEC panel. Fuses and relays are easily identied by referring to the decals inside the TEC covers.
W3004398
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Design and Function
VN
Note: Refer to the decal inside the TEC cover for vehicles exact fuse descriptions and ratings.
W3002729
Fig. 11: Fuse and Relay Positions (in the top TEC panel, VN)
B11 through B16 B22 through B24 PR1 PR2, PR3 Ignition Expansion Blocks Battery Expansion Blocks Accessory Power Relay Igntion Power Relays
One Accessory an two Ignition Power relays are used to transfer the heavy current load coming from the battery to the Ignition/Accessory circuits. These relays are located on the TEC tray for easy access and replacement.
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Design and Function
VHD
Note: Refer to the decal inside the TEC cover for vehicles exact fuse descriptions and ratings.
W3004362
Fig. 12: Fuse and Relay Positions (in the top TEC panel, VHD)
B11 through B16 PR1 PR2, PR3, PR4, R24 Battery and Ignition Expansion Block Accessory Power Relay Ignition Power Relays
One Accessory and four ignition Power relays are used to transfer the heavy current load coming from the battery to the Ignition/Accessory circuits. These relays are located on the TEC tray for easy access and replacement. PR4 is used in the VHD bodybuilder applications
83
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Troubleshooting
Troubleshooting Fault Code Troubleshooting

Message and Parameter Descriptions
MIDs (message IDs) 128 232 136 140 234 144 130 Description EECU (Engine Electronic Control Unit) SRS (Supplemental Restraint System) ABS (Antilock Braking System Instrument Cluster Center Module Instrument Cluster Left Module VECU (Vehicle Electronic Control Unit) TECU (Transmission Electronic Control Unit)
PIDs (Parameter IDs) 84 91 100 102 105 110 111 173 175 190
Description Road Speed % Accelerator Pedal Engine Oil Pressure Boost Pressure Air Inlet Temperature Engine Coolant Temperature Coolant Level Pyrometer Engin Oil Temperature Engine Speed
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Troubleshooting
PPIDs (Proprietary Parameter IDs) 69 70 71 72 73 75 77 78 79 86 109 121 122 123 124 125 195 196
Description
Buffered idle switch Pedal switches, supply Cruise control and retarder, supply switch Accelerator pedal and retarder, supply sensors Accelerator control 2 and primary tank, supply sensors Range inhibitor, status solenoid valve Compressor, status solenoid valve Interval wiper, status relay Area inhibitor, status solenoid valve Engine brake torque percent EOG3 drive stage failure MTE (Engine compsressor control output) failure VCB Engine compression brake EPG2 Start and Warmhold EPG1 Engine brake EOL Enable failure Proprietary Diagnostic Data Request Clear Count Proprietary Diagnostic Data/Count Clear Response
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Troubleshooting
FMI Table
SAE Standard FMI value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SAE Text Data Valid, but above normal operating range. Data Valid, but under normal operating range. Intermittent or incorrect data. Abnormally high voltage. Abnormally low voltage. Abnormally low current or open circuit. Abnormally high current or chort circuit. Mechanical system no repsonse Abnormal frequency or Pulse Width Abnormal update rate Abnormal change rate Failure unkown Bad device Out of calibration Special instruction (see Note)
Note: The special instruction FMI 14 is broadcast when the airbag has stored crash data. Engine-specic for Injectors FMI value 2 3 4 5 Explanation Short circuit to battery voltage, unit injector high side. Short circuit to battery voltage, unit injector low side. Short circuit to ground, unit injector high or low side. Open circuit in the unit injector circuit.
Engine-specic for Injection Pump FMI value 2 3 4 5 6 8 Explanation Short circuit to battery voltage, injection pump high side. Short circuit to battery voltage, injection pump low side. Short circuit to ground, injection pump high or low side. Open circuit in the unit injection pump circuit. Short circuit to ground, injection pump high side. Injection pump current too high for long period of time.
87
Group 28
Troubleshooting
Reading/Clearing Fault Codes

Fault codes can be read and cleared using the VCADS Pro tool or the Pro-Link tool with Volvo application cartridge. See the appropriate service information for details on reading and clearing fault codes using VCADS Pro or Pro-Link tools. On VN-series vehicles, fault codes also can be accessed, read, and cleared via the instrument cluster graphic display. Clearing fault codes is password protected. For information, see Instrumentation VN, from 3/99 and VHD, Volvo Service Publication PV776TSP139790. The Data Link Instrument cluster used WX-series vehicles can access and read a limited number of fault codes. However, it does not have the ability to clear fault codes. For more information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
Fault Tracing Strategy

CAUTION
Check that the proper cable and connector location is observed and used while connecting to the ECU. Failure to do so may result in permanent damage to the ECU or the tool. Generally, the fault tracing strategy employed in this section follows a set sequence in which measurements are taken at specic points in the vehicle wiring. The three basic elements in this strategy are:
W3003493
1 2 3
Vehicle Electronic Control Unit (VECU) The actual component being tested (varies with each fault code) Wiring between VECU and the component being tested
The following information describes the three test strategies:

88
Measurement at the Components Connector, to the VECU page 90 Check of Component page 90 Check of the Subsystem page 91
Group 28
Troubleshooting
Measurement at the Components Connector, to the VECU

In this procedure, the component is disconnected and measurements are made at specic pin locations on the wiring harness end of the connector. Measurements usually involve supply, ground, and signal wire connections through the wiring harness and VECU. Breakout boxes or harnesses may be used to assist in taking measurements. Measurements outside expected values may indicate faults in the wiring or in the VECU itself
W3003494
Check of Component
In this procedure, the component is disconnected and measurements are made at specic pin locations on the component wiring harness or directly to the component. The component is usually a sensor or switch; it is identied at the beginning of each check. Breakout boxes or harnesses may be used to assist in taking measurements. Measurements outside expected values may indicate faults in the component or in the wiring to the component.
W3003495
89
Group 28
Troubleshooting
Check of the Subsystem

In this procedure, the VECU is disconnected, a breakout box is connected between the VECU and wiring harness, and measurements are made at specic pin locations on the breakout box. This check is made to measure the voltage that is present at the VECU with the circuit intact. Measurements outside expected values may indicate faults in the component, wiring, or VECU.
Tests Using the VCADS Pro Tool

The VCADS Pro tool is a Windows95-based PC tool that is used to program, test, and read information from the VECU and EECU. A number of real time tests can be performed by connecting the VCADS Pro tool to the vehicles diagnostic connector. If a test in the VCADS Pro tool may be of benet when troubleshooting a specic fault code, that test will be referenced in the section titled, Appropriate tests in the VCADS Pro tool. Note: Not all tests will apply to all vehicle variants. When starting VCADS Pro, menu selections for various vehicles and engines are entered. Only those tests that apply will be available for selection. For information about the proper operation of the VCADS Pro tool, please refer to VCADS Pro Service Information in group 0.
W0001632
90
Group 28
Troubleshooting
MID 128 EECU

MID 128 Fault Code Table
MID:Message Identication Description. PID:Parameter Identication Description. Error code MID 128-PID 45 MID 128-PID 49 MID 128-PID 84 MID 128-PID 85 Component/Function Preheater Status ABS Control Status Road speed Cruise Control Status SID:Subsystem Identication Description. FMI:Failure Mode Identier. FMI 3, 4, 5 9 9, 11 9 Section MID 128 PID 45 Preheater Status page 96 MID 128 PID 49 ABS Control Status page 98 MID 128 PID 84 Road Speed page 100 MID 128 PID 85 Cruise Control Status page 102 MID 128 PID 91 Accelerator Pedal Position page 104 MID 128 PID 94 Fuel Delivery Pressure page 106 MID 128 PID 100 Engine Oil Pressure page 110 MID 128 PID 102 Boost Pressure page 114 MID 128 PID 105 Boost Air Temperature page 118 MID 128 PID 107 Air Filter Differential Pressure page 122 MID 128 PID 108 Atmospheric Pressure page 125 MID 128 PID 110 Engine Coolant Temperature page 126 MID 128 PID 111 Coolant Level page 129 MID 128 PID 158 Battery Voltage page 131 MID 128 PID 172 Air Inlet Temperature page 133 MID 128 PID 174 Fuel Temperature page 136
MID 128-PID 91
Accelerator Pedal Position
9, 11
MID 128-PID 94
Fuel Delivery Pressure (D7C and D12C only) Engine Oil Pressure
1, 3, 4
MID 128-PID 100
1, 3, 4
MID 128PID 102
Boost Pressure
3, 4
MID 128PID 105
Boost Air Temperature
3, 4
MID 128PID 107
Air Filter Differential Pressure
0, 3, 4, 5
MID 128PID 108
Atmospheric Pressure
3, 4
MID 128PID 110
Engine Coolant Temperature
0, 3 ,4
MID 128PID 111 MID 128PID 158 MID 128PID 172
Coolant level Battery Voltage Air Inlet Temperature
1 3 3, 4
MID 128PID 174
Fuel Temperature (D7C and D12C only)
3, 4
91
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Troubleshooting
Error code MID 128PID 175
Component/Function Engine Oil Temperature
FMI 0, 3, 4
Section MID 128 PID 175 Engine Oil Temperature page 140 MID 128 PID 228 Road Speed Sensor Calibration page 144 MID 128 PPID 86 Engine Brake Torque Percent page 146 MID 128 PPID 119 High Coolant Temperature page 148 MID 128 PPID 122 VCB Engine Compression Brake page 151 MID 128 PPID 123 EPG 2 page 153 MID 128 PPID 124 EPG 1 page 155 MID 128 SID 1/2/3/4/5/6 Injector page 157 MID 128 SID 17 Fuel Shutoff Valve page 161 MID 128 SID 20 Timing Sleeve page 163 MID 128 SID 21 Engine Position Timing Sensor page 166 MID 128 SID 21 Needle Lift Sensor page 168 MID 128 SID 22 Engine Speed Sensor page 170 MID 128 SID 23 Rack Actuator page 172 MID 128 SID 24 Rack Position Sensor page 175 MID 128 SID 33 Fan Control page 177 MID 128 SID 64 Redundant Engine Speed Sensor page 179 MID 128 SID 70 Preheater Element 1 page 181
MID 128PID 228
Road Speed Sensor Calibration Engine Brake Torque Percent
11
MID 128PPID 86
MID 128PPID 119
High Coolant Temperature
MID 128PPID 122
VCB Engine Compression Brake (D12B adn D12C only) EPG 2 (D12B adn D12C only) EPG 1 Injector (D12B and D12C only)
3, 4, 5
MID 128PPID 123 MID 128PPID 124 MID 128SID 1-6
3, 4, 5 3, 4, 5 2, 3, 4, 5, 7, 11
MID 128SID 17 MID 128SID 20 MID 128SID 21
Fuel Shutoff Valve (D7C only) Timing Sleeve (D7C only) Engine Position Timing Sensor (D12B and D12C) Needle Lift Sensor (D7C only)
3, 4, 5 2, 3, 4, 5, 6, 7, 8, 11 3, 8
MID 128SID 21
MID 128SID 22
Engine Speed Sensor
2, 3, 8
MID 128SID 23 MID 128SID 24
Rack Actuator (D7C only) Rack Position Sensor (D7C only) Fan Control Redundant Engine Speed Sensor (D7C only) Preheater Element 1
2, 3, 4, 5, 6, 7, 8, 11 2, 13
3, 4, 5 3, 8
MID 128SID 70
3, 4, 5
92
Group 28
Troubleshooting
Error code MID 128SID 71
Component/Function Preheater Element 2 (D12B only) Idle Validation Switch 1
FMI 3, 4, 5
Section MID 128 SID 71 Preheater Element 2 page 183 MID 128 SID 230 Idle Validation Switch 1 page 185 MID 128 SID 231 SAE J1939 Control Link page 187 MID 128 SID 232 5 Volt DC Supply page 189 MID 128 SID 240 Program Memory page 191 MID 128 SID 250 SAE J1587/1708 Information Link page 192 MID 128 SID 253 Data Set Memory EEPROM page 193 MID 128 SID 254 Engine Electronic Control Unit (EECU) page 194
MID 128SID 230
3, 4
MID 128SID 231
SAE J1939 Control Link
2, 9, 11, 12
MID 128SID 232 MID 128SID 240 MID 128SID 250
5 Volt DC Supply Program Memory SAE J1587/1708 Information Link Data Set Memory EEPROM
3, 4 2, 12 12
MID 128SID 253
2, 12
MID 128SID 254
Engine Electronic Control Unit (EECU)
2, 8, 9, 11, 12, 13
93
Group 28
Troubleshooting
94
Group 28
Troubleshooting
MID 128 PID 45 Preheater Status

The preheat relay is provided battery voltage at all times through the supply wire. If the EECU requests preheat operation (based on engine temperature), the control wire will be grounded through the EECU. Preheating is standard on the D7C engine with one preheat relay/element. Preheating is optional on the D12B engine with two preheat relays/elements.
Fault Codes
FMI 3
Short circuit to battery voltage. Conditions for fault code: Reaction from the EECU:
Fault code is set. Yellow lamp is requested.
Output activated. Short circuit to battery voltage on EB31.
Noticeable external symptom: Yellow lamp lights up. The intake air is warm since the preheating relay is on all the time. High current consumption.
Possible cause: Short circuit to battery voltage on wire between preheating relay and EECU. Short circuit in the preheating relay.
FMI 5:
Break Conditions for fault code:
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The EECU switches off the output.
Output switched off. Open circuit.
Possible cause: Blown fuse to the supply for preheating relay. Open circuit in wire between EECU and preheating relay. Open circuit in the preheating relay. Open circuit in supply wire to preheating relay.
Noticeable external symptom: Yellow lamp lights up. The preheating relay is not activated. White smoke for cold start. Difcult to start in extreme cold.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The EECU switches off the output.
FMI 4
Short circuit to ground. Conditions for fault code:
Output switched off. Short circuit to ground on EB31.
Noticeable external symptom: Yellow lamp lights up. The preheating relay is not activated. White smoke for cold start. Difcult to start in extreme cold.
Possible cause: Short circuit to ground on wire between preheating relay and EECU.
95
Group 28
Troubleshooting
MID 128 PID 45 Preheater Status, Check

Special tools: J-43233, J-39200, J-41132
Check of component
Preheating relay
1 Disconnect the control and supply wires to the preheat relay. Ignition key must be in the OFF position. Note: Each relay must be checked independently. Measuring points Control and supply terminals on the preheat relay Optimal value 8.5 J-39200
NOTE!
Check all the particular connectors for loose connections, switch resistance, and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37.
Measurement at the components connector, to the EECU

1 Note: Check the component to verify that each of the following values is correct. Incorrect values can cause this component to fail. 2 Disconnect the control wire (D7C: small blue/red wire; D12B: small solid black wire) at the preheat relay.
Check of Subsystem
Control of the preheating relay
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Note: Test with Preheat ON can only be performed if the EECU requested preheat. Measuring points EB31 / EB9 EB31 / EB9 J-39200 Ground term EB31 with a jumper wire Optimal value B+ (preheat off) 0 V (preheat on) preheat relay clicks on J-41132 J-43233 J-39200
Control wire:
3 Ignition key must be in the OFF position. Measuring points Control wire / alternate ground Optimal value 180 k
J-39200
Supply wire:
4 Measure the voltage at the supply wire (D7C: small solid black wire; D12B: small blue/red wire) using voltmeter J39200. Ignition key must be in the ON position. Measuring points Supply wire / alternate ground Optimal value B+
96
Group 28
Troubleshooting
MID 128 PID 49 ABS Control Status

Applies only to vehicles with ABS.
Fault Codes
FMI 9
Status message from the ABS control unit is not available (SAE J1587 message). Conditions for fault code:
PID 49 the message is unavailable or is not being updated regularly.
Possible cause:
Error in the information link (SAE J1587). Error from the ABS control unit.
Reaction from the EECU: Fault code is set. Yellow lamp is requested.
Noticeable external symptom: Yellow lamp lights up.
97
Group 28
Troubleshooting
MID 128 PID 49 ABS Control Status, Check

NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37. Also check if the ABS system has any active fault codes. This fault code could be due to the fact that there is a fault in the ABS system.
Check of Subsystem
Check of the SAE J1587 Information link
1 Ignition key must be in the OFF position. Connect breakout box J-41132 in series between connector EB and the EECU. 2 Connect jumper harness J-43233 in series between connector EA and the EECU. Measuring points EB25 / DCA (connection A in diagnostics connector) EB26 / DCB (connection B in diagnostics connector) Optimal value <1
J-41132 J-43233 J-39200
<1
98
Group 28
Troubleshooting
MID 128 PID 84 Road Speed Fault Codes

FMI 9
Vehicle road speed signal not available (SAE J1587 message). Conditions for fault code:
PID 84 the message is unavailable or is not being updated regularly.
Possible cause: Fault in speed sensor. Fault in the information link (SAE J1587). Error from the vehicle ECU (VECU).
Reaction from the EECU: Fault code is set. Yellow lamp is requested. If FMI 11 has also been set, the EECU limits the engine speed to approx. 1700 rpm.
Noticeable external symptom: Yellow lamp lights up. If FMI 11 has also been set, the maximum engine speed is approx. 1700 rpm.
FMI 11
Vehicle road speed signal not available. (SAE J1939 message). Conditions for fault code:
The vehicle speed signal is not available on the communications link (SAE J1939).
Possible cause: Fault in speed sensor. Fault in the communications link (SAE J1939). Fault in VECU.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The message is read from the information link (SAE J1587) instead. If FMI 9 has also been set, the EECU limits the engine speed to approx. 1700 rpm.
Noticeable external symptom: Yellow lamp lights up. If FMI 9 has also been set, the maximum engine speed is approx. 1700 rpm.
99
Group 28
Troubleshooting
MID 128 PID 84 Road Speed, Check

NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37. Also check the speed sensor and the VECU. This fault code could be due to the fact that there is a fault in any of these components.
Check of Subsystem
J-41132 J-43233 J-39200
<1
100
Group 28
Troubleshooting
MID 128 PID 85 Cruise Control Status Fault Codes

FMI 9
Status message from Cruise Control is not available (SAE J1587 message). Conditions for fault code:
PID 85 the message is unavailable or not being updated regularly.
Possible cause:
Fault in the information link (SAE J1587). Fault in the VECU.
101
Group 28
Troubleshooting
MID 128 PID 85 Cruise Control Status, Check

NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37. Also check the cruise control switch and VECU. This fault code could be due to the fact that there is a fault in any of these components.
Check of Subsystem
J41132 J-43233 J-39200
<1
102
Group 28
Troubleshooting
MID 128 PID 91 Accelerator Pedal Position Fault Codes

FMI 9
Accelerator pedal message not available. (SAE J1587 message) Conditions for fault code: the Limp home mode. Noticeable external symptom:
PID 91 message is unavailable or not being updated regularly.
Yellow lamp lights up. If FMI 9 has also been set, the engine will be put in the Limp home mode and the buffered idle validation switch is used instead of the accelerator pedal position sensor.
Possible cause:
Fault in the accelerator pedal. Fault in the information link (SAE J1587). Error from the VECU.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. If FMI 11 has also been set, the EECU will switch to the Limp home mode.
Noticeable external symptom:
Yellow lamp lights up. If FMI 11 has also been set, the engine will be put in the Limp home mode and the buffered idle validation switch is used instead of the accelerator pedal position sensor.
FMI 11
Accelerator pedal faulty. (SAE J1939 message) Conditions for fault code:
Faults in the accelerator pedal sensor are sent on the communications link (SAE J1939). The accelerator pedal signal is not available on the communications link (SAE J1939).
Possible cause:
Fault in the accelerator pedal. Fault in the communications link (SAE J1939). Error from the VECU.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. Accelerator pedal signal is retrieved instead from the information link (SAE J1587). If FMI 9 has also been set, the EECU will switch to 103
Group 28
Troubleshooting
MID 128 PID 91 Accelerator Pedal Position, Check

NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37. Also check the accelerator pedal and the VECU. This fault code could be due to the fact that there is a fault in any of these components.
Check of Subsystem
J-41132 J-43233 J-39200
<1
104
Group 28
Troubleshooting
MID 128 PID 94 Fuel Delivery Pressure D7C and D12C

In addition to the fuel pressure, the sensor also measures the fuel temperature.
Fault Codes
FMI 1
Pressure too low. Conditions for fault code:
Short circuit to voltage, signal wire. Fault in sensor.
The voltage on EA27 is below the alarm limit.
Possible cause: Clogged fuel lter. Air in fuel system. Opening pressure too low on overow valve. Worn out fuel pump. Mechanical fault in sensor.
FMI 4
The voltage on EA27 is under 0.08 V.
Possible cause: Break, 5 V supply wire. Break, signal wire. Break, ground wire. Short circuit to ground, 5 V supply wire. Short circuit to ground, signal wire. Fault in sensor
Noticeable external symptom: Yellow lamp lights up. Low power output. Difcult to start. Blue smoke.
FMI 3
Short circuit to voltage or permanent loss of signal. Conditions for fault code:
Possible cause: Short circuit to voltage, 5 V supply wire
105
Group 28
Troubleshooting
MID 128 PID 94 Fuel Delivery Pressure, Check D7C and D12C
Special tools: J-43233, J-39200, J-41132, 9998534
Signal wire:
5 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 2 / alternate ground Optimal value 100 k
J-39200
NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37.

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector for the fuel pressure sensor. Install breakout harness 9998534 to the wiring harness end only.
Check of component
Fuel pressure sensor
1 Disconnect the connector for the fuel pressure sensor. Install breakout harness 9998534 to the sensor connector only. 2 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 1/4 Optimal value 11 k
40 k
40 k
open circuit open circuit open circuit 9998534
J-39200
9998534
Ground wire:
3 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 4 / alternate ground Optimal value <1 J-39200
1/2 2/4 1 / alternate ground 2 / alternate ground 4 / alternate ground
Supply wire:
4 Measure the voltage with voltmeter J39200. Ignition key must be in the ON position. Measuring points 1 / alternate ground 106 Optimal value 5V J-39200
Group 28
Troubleshooting
Check of Subsystem
Fuel Pressure
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EA and the EECU. Connect jumper harness J43233 in series between connector EB and the EECU. Measuring points EA27 / EA5 Optimal value 0.5 V (engine not running) J-41132 J-43233 J-39200
Note: For fuel pressure/voltage chart, see page 109.
107
Group 28
Troubleshooting
Fuel Pressure Sensor, Pressure/Voltage Chart
W2002799
108
Group 28
Troubleshooting
MID 128 PID 100 Engine Oil Pressure

In addition to the oil pressure, the sensor also measures the oil temperature.
Fault Codes
FMI 1
Pressure too low. Conditions for fault code:
Fault in sensor.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The EECU stops sending PID 100.
Possible cause: Fault in overow valve. Oil level too low. Contaminated oil, slow-owing or too thin. Worn oil pump. Fault in sensor.
Noticeable external symptom: Yellow lamp lights up. The oil pressure gauge shows 0.
FMI 4
Short circuit to ground or open circuit. Conditions for fault code:
Reaction from the EECU: Fault code is set. Power reduction in the rst stage and shutdown in 2nd stage (if engine protection is chosen in the data set).
Possible cause: Break, 5 V supply wire. Break, signal wire. Short circuit to ground, 5 V supply wire. Short circuit to ground, signal wire. Fault in sensor.
LED lights up at the oil pressure gauge. Power reduction (if engine protection is chosen in the data set). Engine shut-down if the vehicle speed falls below 5 mph (3 km/h), if engine protection is chosen in the data set.
Reaction from the EECU:
FMI 3
Short circuit to voltage. Conditions for fault code:
Fault code is set. Yellow lamp is requested. The EECU stops sending PID 100.
The voltage on EA14 exceeds 4.95 V.
Possible cause: Short circuit to battery voltage, 5 V supply wire. Short circuit to battery voltage or 5 V, signal wire.
Noticeable external symptom: Yellow lamp lights up. The oil pressure gauge shows 0.
109
Group 28
Troubleshooting
MID 128 PID 100 Engine Oil Pressure, Check

Signal wire:
J-39200
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the oil pressure sensor. Install breakout harness 9998534 to the wiring harness end only.
Check of component
Oil pressure sensor
1 Disconnect the connector to the oil pressure sensor. Install breakout harness 9998534 to the sensor harness end only. 9998534
9998534
2 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points Optimal value 11 k
40 k
40 k
open circuit open circuit open circuit
J-39200
Ground wire:
1/4 1/2 2/4 1 / alternate ground 2 / alternate ground 4 / alternate ground
Supply wire:
4 Measure the voltage with voltmeter J39200. Ignition key must be in the ON position. Measuring points 1 / alternate ground Optimal value 5V J-39200
110
Group 28
Troubleshooting
Check of Subsystem
Oil pressure
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EA and the EECU. Connect jumper harness J43233 in series between connector EB and the EECU. Measuring points EA14 / EA5 Optimal value 0.5 V (engine not running) J-41132 J-43233 J-39200
Note: For oil pressure/voltage chart, see Oil Pressure Sensor, Pressure/Voltage Chart page 113.
111
Group 28
Troubleshooting
Oil Pressure Sensor, Pressure/Voltage Chart
W2002732
112
Group 28
Troubleshooting
MID 128 PID 102 Boost Pressure

In addition to the boost pressure, the sensor also measures the boost air temperature.
Fault Codes
FMI 3
Possible cause: Short circuit to battery voltage, 5 V supply wire. Short circuit to battery voltage or 5 V, signal wire. Fault in sensor.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The EECU stops sending PID 102. Power reduction.
Yellow lamp lights up. The boost pressure gauge shows 0. Low power output. FMI 4
Possible cause: Break, 5 V supply wire. Break, signal wire. Short circuit to ground, 5 V supply wire. Short circuit to ground, signal wire. Fault in sensor.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The EECU stops sending PID 102. Power reduction.
Noticeable external symptom: Yellow lamp lights up. The boost pressure gauge shows 0. Low power output.
113
Group 28
Troubleshooting
MID 128 PID 102 Boost Pressure, Check

Signal wire:
J-39200
NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VN/VHD, Electrical Schematics, Group 37.

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect.
Check of component
Boost pressure sensor
1 Disconnect the connector to the boost pressure sensor. Install breakout harness 9998534 to the sensor harness end only. 9998534 J-39200
2 Disconnect the connector to the boost pressure sensor. Install breakout harness 9998534 to the wiring harness end only.
9998534
Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 1/4 Optimal value 11.5 k
44 k
44 k
open circuit open circuit open circuit
Ground wire:
1/2 2/4 1 / alternate ground 2 / alternate ground 4 / alternate ground
Supply wire:
4 Measure the voltage with voltmeter J39200. Ignition key must be in the ON position. Measuring points 1 / alternate ground 114 Optimal value 5V J-39200
Group 28
Troubleshooting
Check of Subsystem
Boost pressure
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EA and the EECU. Connect jumper harness J43233 in series between connector EB and the EECU. Measuring points EA3 / EA5 Optimal value 1.2 V (sea level, engine not running) J-41132 J-43233 J-39200
Note: For boost pressure/voltage chart, see Boost Pressure Sensor, Pressure/Voltage Chart page 117.
115
Group 28
Troubleshooting
Boost Pressure Sensor, Pressure/Voltage Chart
W2002730
116
Group 28
Troubleshooting
MID 128 PID 105 Boost Air Temperature

In addition to the boost air temperature, the sensor also measures the boost pressure. The boost air temperature signal can be used to switch on the radiator fan.
Fault Codes
FMI 3
Short circuit to voltage or open circuit. Conditions for fault code:
Possible cause: Short circuit to voltage, signal wire. Short circuit to voltage, ground wire. Break, signal wire. Break, ground wire. Fault in sensor.
FMI 4
Possible cause: Short circuit to ground, signal wire. Fault in sensor.
117
Group 28
Troubleshooting
MID 128 PID 105 Boost Air Temperature, Check

Signal wire:
5 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 3 / alternate ground Optimal value 5.7 k
J-39200
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the boost air temperature sensor. Install breakout harness 9998534 to the wiring harness end only.
Check of component
Boost air temperature sensor
1 Disconnect the connector to the boost air temperature sensor. Install breakout harness 9998534 to the sensor harness only. 9998534 J-39200
9998534
Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 3/4 Optimal value 6.2 k
(20 C/68 F)

Ground wire:
3/4 1 / alternate ground 2 / alternate ground 4 / alternate ground
2.5 k
(40 C/104 F) open circuit open circuit open circuit
Supply wire:
4 Measure the voltage with voltmeter J39200. Ignition key must be in the ON position. Measuring points 1 / alternate ground Optimal value 5V J-39200 Note: For boost air temperature/resistance chart, see Boost Air Temperature Sensor, Temperature/Resistance Chart page 121.
118
Group 28
Troubleshooting
Check of Subsystem
Boost air temperature
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EA and the EECU. Connect jumper harness J43233 in series between connector EB and the EECU. Measuring points EA2 / EA5 EA2 / EA5 Optimal value 2.6 V (20 C/68 F) 1.6 V (40 C/104 F)

J-41132 J-43233 J39200
Note: For boost air temperature/resistance chart, see Boost Air Temperature Sensor, Temperature/Resistance Chart page 121.
119
Group 28
Troubleshooting
Boost Air Temperature Sensor, Temperature/Resistance Chart
W2002728
120
Group 28
Troubleshooting
MID 128 PID 107 Air Filter Differential Pressure

(D12B, D12C, D7C Engines)
W2003315
Fault Codes
FMI 0
Filter restriction is too great. The pressure drop (lter restriction) is greatest at high engine speed/load. With current engine software, once PID 107 is triggered, it remains active until the ignition is turned to the OFF position. At that time, the fault code is reset (neither active nor inactive) until the fault condition recurs. Conditions for fault code:
Yellow lamp is requested.
Possible checks: MID 128 PID 107 Air Filter Differential Pressure, Check page 124.
Filter restriction too great. Voltage between EB17EB8 exceeds 3.25 0.25 V.
Possible cause: Clogged air lter. Fault in sensor.
Noticeable external symptom: Yellow lamp is illuminated. Loss of tractive power.

T2012730
Possible action: Check/replace the air lter. See Service Bulletin, Checklist A: Turbo Boost Pressure, publication number PV776200040SB.
Fig. 13: 7084 - air lter restriction/temperature sensor; 9070 - EECU.
FMI 3
Short circuit to battery voltage. Conditions for fault code:
Voltage between EB17EB8 exceeds 11.1 V.
Possible cause: Short circuit to battery voltage, signal wire. Short circuit to battery voltage, ground wire. Fault in sensor.
Reaction from the EECU: Fault code is set. 121
Group 28
Troubleshooting
FMI 4
Voltage between EB17EB8 is under 1.1 V.
FMI 5:
Break Conditions for fault code:
Voltage between EB17EB8 exceeds 7.7 V.
Possible cause: Break in signal wire. Fault in sensor.
122
Group 28
Troubleshooting
MID 128 PID 107 Air Filter Differential Pressure, Check

Check of Component
Note: Faults in the component can be caused by faults in the wiring harness of the EECU. Thus, a check of the wiring harness should also be made before connecting a new component.
Special tools: 9998534, J-39200, J-43233, J41132
Air Filter Restriction/Temperature Sensor
NOTE!
Check all the particular connectors for loose connections, switch resistance, and oxidation. For detailed circuit information, refer to VN/VHD, Electrical Schematics, Group 37.
1 Disconnect the connector to the air lter restriction/temperature sensor. Install breakout harness 9998534 to the sensor harness end only. 2 Measure the resistance with DMM J39200. Ignition key must be in the OFF position. Measuring points 1/2 1/2 Optimal value 330
(inactive; normal position) 2.2 k
(active)
9998534
Measurement at the Components Connector, to the EECU

1 Note: Check to verify that each of the following values is correct. Incorrect values can also cause this component to fail. It is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the air lter restriction/temperature sensor. Install breakout harness 9998534 to the wiring harness only.
J-39200
9998534
Check of Subsystem
Air Filter Indicator
Ground wire:
3 Measure the resistance using DMM J39200. Ignition key must be in the OFF position. Measuring points 2 / alternate ground Optimal value <1 J-39200
1 Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. 2 Measure the voltage with DMM J39200. Ignition key must be in the ON position. Measuring points EB8 / EB17 Optimal value 1.35 V (inactive; normal position) 5.1 V (active)
J-41132 J-43233 J-39200
Signal wire/supply wire:

4 Measure the voltage at the supply wire using DMM J-39200. Ignition key must be in the ON position. Measuring points 1 / alternate ground Optimal value 80% B+ J-39200
123
Group 28
Troubleshooting
MID 128 PID 108 Atmospheric Pressure

The sensor is located inside the EECU and therefore cannot be checked. The signal is used to calculate the turbo pressure and to compensate the fuel when driving at high altitudes.
Fault Codes
FMI 3
The signal from the internal sensor exceeds 4.95 V.
Possible cause: Internal fault in the EECU. The EECU has been exposed to extremely high pressure.
Noticeable external symptom: Yellow lamp lights up. Poor response at high altitudes.
FMI 4
The signal from the internal sensor is under 0.08 V.
Possible cause: Internal fault in the EECU. The EECU has been exposed to extremely low pressure.
Noticeable external symptom: Yellow lamp lights up. Poor response at high altitudes.
124
Group 28
Troubleshooting
MID 128 PID 110 Engine Coolant Temperature Fault Codes

FMI 0
Temperature too high. Conditions for fault code: Reaction from the EECU:
The coolant temperature exceeds 102 C/216 F.
Fault code is set. Yellow lamp is requested. The EECU stops sending PID 110.
Possible cause: Low coolant level. Fault in thermostat. Clogged radiator (internally/externally). Clogged intercooler (on the outside). Poor through-ow in the cooling system. Worn coolant pump. Fault in pressure cap, expansion tank. Fault in sensor.
Noticeable external symptom: Yellow lamp lights up. The coolant temperature gauge shows 0.
FMI 4
Reaction from the EECU: Fault code is set. Power reduction in the rst stage. The engine is shut down in the second stage (if engine protection is chosen in the data set).
LED lights up at the coolant temperature gauge. Low power output. The engine is shut down (if engine protection is chosen in the data set).
Noticeable external symptom: Yellow lamp lights up. The coolant temperature gauge shows 0.
FMI 3
Possible cause: Short circuit to battery or 5 V voltage, signal wire. Short circuit to voltage, ground wire. Break, signal wire. Break, ground wire. Fault in sensor.
125
Group 28
Troubleshooting
MID 128 PID 110 Engine Coolant Temperature, Check

Check of component
Coolant temperature sensor
1 Disconnect the connector to the coolant temperature sensor. Install breakout harness 9998534 to the sensor harness only. Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Note: For coolant temperature/resistance chart, see Coolant Temperature Sensor, Temperature/Resistance Chart page 128. Measuring points 1/2 1/2 Optimal value 1.9 k
(20 C/68 F)

9998534 J-39200
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the coolant temperature sensor. Install breakout harness 9998534 to the wiring harness end only.
9998534 1 / alternate ground 2 / alternate ground
160
(85 C/185 F) open circuit open circuit
Ground wire:
Check of Subsystem
Coolant temperature
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EA and the EECU. Connect jumper harness J43233 in series between connector EB and the EECU. Measuring points Optimal value 3.0 V (20 C/68 F) 0.6 V (85 C/185 F)

J-41132 J-43233 J-39200
Signal wire:
J-39200
EA25 / EA5 EA25 / EA5
Note: For coolant temperature/resistance chart, see Coolant Temperature Sensor, Temperature/Resistance Chart page 128.
126
Group 28
Troubleshooting
Coolant Temperature Sensor, Temperature/Resistance Chart
W2002729
127
Group 28
Troubleshooting
MID 128 PID 111 Coolant Level

The information applies only to the magnetic coolant level sensor that is mounted in the bottom of the radiator expansion tank. Some models (WG, AC) are equipped with a capacitive probe and an electronic coolant level module that converts the capacitive signal to an output signal that the EECU can understand.
Fault Codes
FMI 1
Level too low. Conditions for fault code:
Coolant level switch closed. The voltage on EB7 is under 45% of the battery voltage.
Possible cause:
Low coolant level. Short circuit to ground, signal wire. Fault in sensor.
Reaction from the EECU: Fault code is set. Red lamp is requested. The EECU reduces the output after 30 seconds and shuts down the engine if the vehicle speed goes under 5 mph or 3 km/h (if engine protection is chosen in the data set).
Red lamp lights up. The EECU reduces the output after 30 seconds and shuts down the engine if the vehicle speed goes under 5 mph or 3 km/h (if engine protection is chosen in the data set).
128
Group 28
Troubleshooting
MID 128 PID 111 Coolant Level, Check

Special tools: J-43233, J-39200, J-41132, J42472
Check of component
The coolant level sensor
1 Disconnect the connector to the coolant level sensor. Install breakout harness J-42472 to the sensor harness end only. Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 1/2 Optimal value open circuit (coolant level normal) <1
(coolant level low) open circuit open circuit J-39200 J-42472
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the coolant level sensor. Install breakout harness J-42472 to the wiring harness end only.
1/2 1 / alternate ground 2 / alternate ground
J-42472
Ground wire:
Check of Subsystem
Coolant level
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Measuring points EB7 / EB8 Optimal value 80% B+ (open, coolant level normal) 0 V (closed, coolant level low) J-41132 J-43233 J-39200
Signal wire:
J-39200
EB7 / EB8
129
Group 28
Troubleshooting
MID 128 PID 158 Battery Voltage Fault Codes

FMI 3
Battery voltage too high. Conditions for fault code:
The battery voltage exceeds 36 V.
Possible cause: Fault in alternator. Fast charger connected.
130
Group 28
Troubleshooting
MID 128 PID 158 Battery Voltage, Check

NOTE!
Check of Subsystem
EECU supply relay
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Measuring points EB9 / EB11 EB10 / EB12 EB9 / EB10 EB11 / EB12 Optimal value B+ B+ J-41132 J-43233 J-39200
<1
<1
131
Group 28
Troubleshooting
MID 128 PID 172 Air Inlet Temperature

An ambient air temperature sensor is mounted in the piping between the air lter and the turbo inlet. In addition to ambient air temperature, the sensor also measures air lter restriction. The air lter restriction function is currently not used.
Fault Codes
FMI 3
The voltage on EB3 exceeds 4.95 V.
Noticeable external symptom: Yellow lamp lights up. Blue smoke in cold weather conditions.
FMI 4

132
The voltage on EB3 is under 0.08 V.
Noticeable external symptom: Yellow lamp lights up. Blue smoke in cold weather conditions.
Group 28
Troubleshooting
MID 128 PID 172 Air Inlet Temperature, Check

Check of component
Air temperature sensor
1 Disconnect the connector to the ambient air temperature sensor. Install breakout harness 9998534 to the sensor harness end only. Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Note: For ambient air temperature/resistance chart, see Ambient Air Temperature Sensor, Temperature/Resistance Chart page 135. Measuring points 3/4 Optimal value 5.7 k
(20 C/68 F)

NOTE!
9998534 J-39200

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the ambient air temperature sensor. Install breakout harness 9998534 to the wiring harness only.
9998534
Check of Subsystem
Ambient air temperature inlet
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Measuring points EB3 / EB13 EB3 / EB13 Optimal value 2.6 V (20 C/68 F) 1.2 V (50 C/122 F)

Ground wire:
J-41132 J-43233 J-39200
Signal wire:
J-39200
Note: For ambient air temperature/resistance chart, see Ambient Air Temperature Sensor, Temperature/Resistance Chart page 135.
133
Group 28
Troubleshooting
Ambient Air Temperature Sensor, Temperature/Resistance Chart
W2002733
134
Group 28
Troubleshooting
MID 128 PID 174 Fuel Temperature D7C and D12C

In addition to the fuel temperature, the sensor also measures the fuel pressure. The signal is used for fuel density compensation.
Fault Codes
FMI 3
Noticeable external symptom: Yellow lamp lights up. Incorrect fuel quantity.
FMI 4
Noticeable external symptom: Yellow lamp lights up. Incorrect fuel quantity.
135
Group 28
Troubleshooting
MID 128 PID 174 Fuel Temperature, Check

Signal wire:
J-39200
D7C and D12C

Note: Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37.

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the fuel temperature sensor. Install breakout harness 9998534 to the wiring harness end only.
Check of component
Fuel temperature sensor
1 Disconnect the connector to the fuel temperature sensor. Install breakout harness 9998534 to the sensor connector only. 9998534 J-39200
9998534
Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Note: For fuel temperature/resistance chart, see Fuel Temperature Sensor, Temperature/Resistance Chart page 139.
Ground wire:
Measuring points 3/4 3/4 1 / alternate ground 3 / alternate ground J-39200 4 / alternate ground
Optimal value 1.9 k

(20 C/68 F)

800
(40 C/104 F) open circuit open circuit open circuit
Supply wire:
4 Measure the voltage with voltmeter J39200. Ignition key must be in the ON position. Measuring points 1 / alternate ground Optimal value 5V
136
Group 28
Troubleshooting
Check of Subsystem
Fuel temperature

J-41132 J-43233 J-39200
Note: For fuel temperature/resistance chart, see Fuel Temperature Sensor, Temperature/Resistance Chart page 139.
137
Group 28
Troubleshooting
Fuel Temperature Sensor, Temperature/Resistance Chart
W2002742
138
Group 28
Troubleshooting
MID 128 PID 175 Engine Oil Temperature

In addition to the oil temperature, the sensor also measures the oil pressure.
Fault Codes
FMI 0
Temperature too high. Conditions for fault code:
FMI 4

The oil temperature exceeds 130 C (266 F).
Possible cause: Poor cooling capacity. Fault in sensor.
Reaction from the EECU: Fault code is set. Red lamp is requested.
Noticeable external symptom: Red lamp lights up. Power reduction in the rst stage (at 130 C (266 F) and shutdown in 2nd stage (if engine protection is chosen in the data set).

Yellow lamp lights up. The oil temperature gauge shows 0.
FMI 3
Noticeable external symptom: Yellow lamp lights up. The oil temperature gauge shows 0.
139
Group 28
Troubleshooting
MID 128 PID 175 Engine Oil Temperature, Check

Signal wire:
J-39200
NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VN/VHD, Electrical Schematics, Group 37.

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the oil temperature sensor. Install breakout harness 9998534 to the wiring harness end only.
Check of component
Oil temperature sensor
1 Disconnect the connector to the oil temperature sensor. Install breakout harness 9998534 to the sensor harness end only. 9998534 J-39200
9998534
Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Note: For oil temperature/resistance chart, see Oil Temperature Sensor, Temperature/Resistance Chart page 143.
Ground wire:
Measuring points 3/4 3/4
Optimal value 1.9 k

(20 C/68 F)

100
(100 C/212 F)
Supply wire:
140
Group 28
Troubleshooting
Check of Subsystem
Oil temperature

J-41132 J-43233 J-39200
Note: For oil temperature/resistance chart, see Oil Temperature Sensor, Temperature/Resistance Chart page 143.
141
Group 28
Troubleshooting
Oil Temperature Sensor, Temperature/Resistance Chart
W2002727
142
Group 28
Troubleshooting
MID 128 PID 228 Road Speed Sensor Calibration Fault Codes
FMI 11
K factor message not available on the information link (SAE J1587). Conditions for fault code:
PID 228 the message is not available on the information link (SAE J1587).
Possible cause:
Fault in the information link (SAE J1587). Error from the VECU.
143
Group 28
Troubleshooting
MID 128 PID 228 Road Speed Sensor Calibration, Check

Special tools: J43233, J-39200, J-41132
NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37. Also check the VECU. This fault code could be due to the fact that there is a fault in the VECU.
Check of Subsystem
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Measuring points EB25 / DCA (connection A in diagnostics connector) EB26 / DCB (connection B in diagnostics connector) Optimal value <1 J-41132 J-43233 J-39200
<1
144
Group 28
Troubleshooting
MID 128 PPID 86 Engine Brake Torque Percent Fault Codes

FMI 9
Engine brake torque information is not available (SAE J1587 message). Conditions for fault code:
PPID 86 the message is not available on the information link (SAE J1587).
Possible cause:
Fault in the information link (SAE J1587). Error from the VECU.
145
Group 28
Troubleshooting
MID 128 PPID 86 Engine Brake Torque Percent, Check

NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37. Also check the VECU. This fault code could be due to the fact that there is a fault in the VECU.
Check of Subsystem
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Measuring points EB25 / DCA (connection A in diagnostics socket) EB26 / DCB (connection B in diagnostics socket) Optimal value <1 J-41132 J-43233 J-39200
<1
146
Group 28
Troubleshooting
MID 128 PPID 119 High Coolant Temperature

D12B, D12C, D7C Engines
Fault Codes
FMI 0
Temperature too high. Conditions for fault code:
The coolant temperature exceeds 102 C (216 F).
Possible cause: Low coolant level. Fault in thermostat. Clogged radiator (internally/externally). Clogged intercooler (on the outside). Poor through-ow in the cooling system. Worn coolant pump. Fault in pressure cap, expansion tank. Fault in sensor.
Reaction from the EECU: Fault code is set. Power reduction in the rst stage. The engine is shut down in the second stage (if engine protection is chosen in the data set).
LED lights up at the coolant temperature gauge. Low power output. The engine is shut down (if engine protection is chosen in the data set).
Possible checks:
MID 128 PPID 119 High Coolant Temperature, Check page 149.
147
Group 28
Troubleshooting
MID 128 PPID 119 High Coolant Temperature, Check

Check of Component
Note: Faults in the component can be caused by faults in the wiring harness of the EECU. Thus, a check of the wiring harness should also be made before connecting a new component.
Special tools: 9998534, J-43233, J-39200, J41132
Coolant Temperature Sensor

1 Disconnect the connector to the coolant temperature sensor. Install breakout harness 9998534 to the sensor harness end only. 2 Measure the resistance with DMM J39200. Ignition key must be in the OFF position. Note: A coolant temperature/resistance chart is available; see System Check in Service Publication 200870, Fault Codes, Engine Electronic Control Unit, order number PV776TSP105620/1. Measuring points Optimal value 1.9 k
/ 20 C (68 F)

NOTE!
9998534
Measurement at the Components Connector, to the EECU

Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 1 Disconnect the connector to the coolant temperature sensor. Install breakout harness 9998534 to the wiring harness end only. 9998534
J-39200
Ground wire:
2 Measure the resistance using DMM J39200. Ignition key must be in the OFF position. Measuring points 2 / alternate ground Optimal value <1 J-39200
1/2 1/2 1 / alternate ground 2 / alternate ground
160
/ 85 C (185 F)

open circuit open circuit
Signal wire:
3 Measure the resistance using DMM J39200. Ignition key must be in the OFF position. Measuring points 1 / alternate ground Optimal value 1.4 k
J-39200
148
Group 28
Troubleshooting
Check of Subsystem
Coolant Temperature
1 Connect breakout box J-41132 in series between connector EA and the EECU. Connect jumper harness J43233 in series between connector EB and the EECU. 2 Measure the voltage using DMM J39200. Ignition key must be in the ON position. Measuring points EA25 / EA5 EA25 / EA5 Optimal value 3.0 V / 20 C (68 F) 0.6 V / 85 C (185 F)

J-41132 J-43233 J-39200
149
Group 28
Troubleshooting
MID 128 PPID 122 VCB Engine Compression Brake D12B and D12C Fault Codes
FMI 3
The output is switched off.
Noticeable external symptom: Yellow lamp lights up. VCB is on all the time. Low power output. Black smoke. Extreme uneven operation.
Output activated. Short circuit to battery voltage on EA33.
Possible cause: Short circuit to battery voltage between the VCB solenoid valve and EECU. Short circuit in VCB solenoid valve.
FMI 5
Break. Conditions for fault code:
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The output is switched off.
Output switched off. Open circuit in the VCB circuit.
Noticeable external symptom: Yellow lamp lights up. Reduced engine brake power because the VCB cannot be activated.
Possible cause: Open circuit between the VCB solenoid valve and EECU. Open circuit in the supply wire to VCB solenoid valve. Blown fuse for supply to VCB solenoid valve. Open circuit in VCB solenoid valve.
FMI 4
Output switched off. Short circuit to ground on EA33.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. Output is switched off.
Possible cause: Short circuit to ground between the VCB solenoid valve and EECU.
Noticeable external symptom: Yellow lamp lights up. Reduced engine brake power because the VCB cannot be activated.
150
Group 28
Troubleshooting
MID 128 PPID 122 VCB Engine Compression Brake, Check

Check of component
Compression brake solenoid, VCB
1 Disconnect the two wires at the compression brake solenoid. The compression brake solenoid is located under the valve cover. Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points Solenoid terminal A / B A / alternate ground B / alternate ground Optimal value 21 J-39200
D12B and D12C

NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the two wires at the compression brake solenoid. The compression brake solenoid is located under the valve cover.
Check of Subsystem
Compression brake, VCB
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EA and the EECU. Connect jumper harness J43233 in series between connector EB and the EECU. Note: Test with VCB On can be performed only if the EECU has requested VCB operation. Measuring points EA33 / alternate ground EA33 / alternate ground J-39200 ground terminal EA33 with a jumper wire Optimal value B+ (VCB off) 0 V (VCB on) VCB solenoid clicks on J-41132 J-43233 J-39200
Ground wire/Control wire:

3 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points Ground control wire / alternate ground Optimal value 215 k
J-39200
Supply wire:
4 Measure the voltage with voltmeter J39200. Ignition key must be in the ON position. Measuring points Supply wire / alternate ground Optimal value B+
151
Group 28
Troubleshooting
MID 128 PPID 123 EPG 2 D12B and D12C Fault Codes
FMI 3
Noticeable external symptom: Yellow lamp lights up. EPG 2 constantly activated. Low power output. Black smoke.
Possible cause: Short circuit to battery voltage between solenoid valve and EECU. Short circuit in solenoid valve.
FMI 5
Reaction from the EECU: Fault code is set. Yellow lamp is requested. EPG1, EPG2 and VCB outputs are switched off.
Output switched off. Open circuit in the EPG2 circuit.
Possible cause: Yellow lamp lights up. The heat retention does not function. Blue smoke under cold conditions. The engine may be difcult to start. Engine brake does not function. Open circuit between solenoid valve and EECU. Open circuit in supply wire to solenoid valve. Blown fuse for supply to EPG2. Open circuit in the solenoid valve.
FMI 4
Noticeable external symptom: Yellow lamp lights up. The heat retention does not function. Blue smoke under cold conditions. The engine may be difcult to start. Engine brake does not function.
Possible cause: Short circuit to ground between solenoid valve and EECU.
Reaction from the EECU: Fault code is set.
152
Group 28
Troubleshooting
MID 128 PPID 123 EPG 2, Check D12B and D12C

Check of component
EPG control (PWM box)
1 Disconnect the connector to the EPG control box. Install breakout harness 9998534 to the EPG control connector only. Ignition key must be in the OFF position. Measuring points 1/3 1 / alternate ground 3 / alternate ground Optimal value 23 9998534 J-39200
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the EPG control box. Install breakout harness 9998534 to the wiring harness end only.
Check of Subsystem
Exhaust pressure governor 2, EPG 2
9998534 1 Ignition key must be in the RUN position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Note: Test with EPG On can be performed only if the EECU has requested EPG 2 operation. Measuring points EB36 / EB9 Optimal value B+, EPG 2 off (Engine running, parking brake released, accelerator pedal above idle) 0 V, EPG 2 on (Engine running, parking brake on, accelerator at idle) J-41132 J-43233 J-39200

J-39200
Supply wire:
4 Measure the voltage with voltmeter J39200. Ignition key must be in the ON position. Measuring points 1 / alternate ground Optimal value B+ J-39200
EB36 / EB9
153
Group 28
Troubleshooting
MID 128 PPID 124 EPG 1 Fault Codes

FMI 3
Noticeable external symptom: Yellow lamp lights up. EPG 1 constantly activated. Low power output. Black smoke.
Possible cause: Short circuit to battery voltage between solenoid valve and EECU. Short circuit in solenoid valve.
FMI 5
Output switched off. Open circuit in the EPG1 circuit.
Possible cause: Yellow lamp lights up. Heat retention does not function. Blue smoke under cold conditions. Engine may be difcult to start. Engine brake does not function. Open circuit between solenoid valve and EECU. Open circuit in supply wire to solenoid valve. Blown fuse for supply to EPG1. Open circuit in the solenoid valve.
FMI 4
Noticeable external symptom: Yellow lamp lights up. Engine brake does not function. Heat retention does not function. Blue smoke under cold conditions. Engine may be difcult to start.
154
Group 28
Troubleshooting
MID 128 PPID 124 EPG 1, Check

Check of component (D12B only)

EPG control (PWM box)
1 Note: This procedure is for the D12B engine only. The D7C engine uses a single EPG solenoid; to check the solenoid used on the D7C, see publication TSI-27060007 (11/96).
NOTE!

2 Disconnect the connector to EPG control. Install breakout harness 9998534 to the EPG control connector only. Ignition key must be in the OFF position. Measuring points 1/4 1 / alternate ground Optimal value 23
9998534 J-39200
2 Disconnect the connector to the EPG control box (D12B) or the EPG solenoid (D7C). Install breakout harness 9998534 to the wiring harness end only.
9998534
4 / alternate ground
Check of Subsystem
Exhaust pressure governor 1, EPG 1
J-39200 1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Note: Test with EPG On can be performed only if the EECU has requested EPG 1 operation. Measuring points EB35 / EB9 J-39200 EB35 / EB9 Optimal value B+ (EPG off) 0 V (EPG on) J-41132 J-43233 J-39200

3 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 4 / alternate ground Optimal value 180
Supply wire:
4 Measure the voltage with voltmeter J39200. Ignition key must be in the ON position. Measuring points 1 / alternate ground Optimal value B+
155
Group 28
Troubleshooting
MID 128 SID 1/2/3/4/5/6 Injector D12B and D12C

Error Code Information Error code SID 1 SID 2 SID 3 SID 4 SID 5 SID 6 Explanation Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6
Fault Codes
FMI 2
Short circuit to battery voltage, injectors high side. Conditions for fault code: Possible cause:
Short circuit between high and low side. Short circuit to battery voltage in the wiring to the injectors low side.
Injector activated. Short circuit to battery voltage on pin EA12 or EA24 (each respective injector banks high side).
Possible cause:
Short circuit to battery voltage in the wiring to the injectors high side.
Fault code is set. Yellow lamp is requested. The particular injector or the whole of the affected injector bank is switched off.
Fault code is set. Yellow lamp is requested. The particular injector bank is switched off.
Noticeable external symptom: Yellow lamp lights up. Low power output. Uneven operation. Abnormal noise. 3 cylinder operation.
Yellow lamp lights up. Low power output. Uneven operation. Abnormal noise. 3 or 5 cylinder operation.
FMI 3
Short circuit to battery voltage or short-circuited injector, injector low side. Conditions for fault code:

156
Injector activated. Short circuit to battery voltage on each respective injectors low side (EA11, EA22, EA23, EA34, EA35, EA36).
Group 28
Troubleshooting
FMI 4
Short circuit to ground, injector low or high side. Conditions for fault code:
3 or 5 cylinder operation.
FMI 7
The mechanical system does not respond in the correct way Conditions for fault code:
Injector activated. Short circuit to ground on each respective injectors low side (EA11, EA22, EA23, EA34, EA35, EA36) or high side (EA12, EA24).
Possible cause:
Injector activated. Cylinder balancing data too high.
Short circuit to ground in the wiring for each respective injectors low or high side.
Possible cause: Fault in injector. Poor compression.
Fault code is set. Yellow lamp is requested. The particular injector bank is switched off.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The particular injector is switched off.
FMI 5
Open circuit in the injector circuit. Conditions for fault code:
FMI 11
Unidentiable error. Conditions for fault code:
Injector activated. Open circuit in the injector circuit.
Injector activated.
Possible cause: Open circuit in the wiring on low or high side. If 3 fault codes have been set (a bank) the open circuit is on that banks high side, if there is only one fault code the open circuit is on the particular injectors low side.
Possible cause: Intermittent faults.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The particular injector or the whole injector bank is switched off.
Fault code is set. Yellow lamp is requested. One or three injectors are switched off.
Noticeable external symptom: Yellow lamp lights up. Low power output. Uneven operation. Abnormal noise.
Yellow lamp lights up. Low power output. Uneven operation. Abnormal noise. 3 or 5 cylinder operation. 157
Group 28
Troubleshooting
MID 128 SID 1/2/3/4/5/6 Injector, Check

Wires
2 Connect breakout box J-41132 to the EA connector, wiring harness end only. DO NOT connect 100pt to the EECU. Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points EA11 / EA12 EA22 / EA12 EA23 / EA12 EA34 / EA24 EA35 / EA24 EA36 / EA24 EA11 / alternate ground EA22 / alternate ground EA23 / alternate ground EA34 / alternate ground EA35 / alternate ground EA36 / alternate ground Optimal value J-39200 J-41132
D12B and D12C

NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37. Note that small resistances are difcult to measure. Use the value instead as a standard value for the open circuit in the injector circuits.

1.7
1.7
1.7
1.7
1.7
1.7 open circuit open circuit open circuit open circuit open circuit open circuit
158
Group 28
Troubleshooting
Check of component
Injectors
1 Disconnect both the connections for each respective injector. Measure the resistance with ohmmeter J-39200 on the injector. Ignition key must be in the OFF position. Measuring points High side / low side High side / alternate ground Low side / alternate ground Optimal value 1.5 - 2.0 J-39200
159
Group 28
Troubleshooting
MID 128 SID 17 Fuel Shutoff Valve

D7C only
Fault Codes
FMI 3
Short circuit to battery voltage. Conditions for fault code: valve and EECU. Reaction from the EECU:
Noticeable external symptom: Yellow lamp lights up. The solenoid valve permanently activated.
Possible cause: Short circuit to battery voltage on wire between solenoid valve and EECU. Short circuit internally in the solenoid valve.
FMI 5
Open circuit in the fuel shut-off circuit. Conditions for fault code:
Output switched off. Open circuit in the fuel shut-off circuit.
Noticeable external symptom: Yellow lamp lights up. Engine stops or does not start. No fuel reaches the nozzle.
Possible cause: Open circuit between solenoid valve and EECU. Open circuit in supply wire to fuel shut-off valve. Open circuit in solenoid valve.
FMI 4
Noticeable external symptom: Yellow lamp lights up. Engine stops or does not start. No fuel reaches the nozzle.
Possible cause: Short circuit to ground on wire between solenoid
160
Group 28
Troubleshooting
MID 128 SID 17 Fuel Shutoff Valve, Check

Check of component
Fuel shut-off valve solenoid
1 Disconnect the connector to the fuel shut-off valve solenoid. Install breakout harness 9998534 to the solenoid harness end only. Ignition key must be in the OFF position. Measuring points 1/2 1 / alternate ground 2 / alternate ground Optimal value 10.7 9998534 J39200
D7C only
1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the fuel shut-off valve solenoid. Install breakout harness 9998534 to the wiring harness end only.
9998534
Check of Subsystem
Fuel shut-off
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Measuring points EB34 / EB9 Optimal value 0V

J-39200
J-41132 J-43233 J-39200
Supply wire:
161
Group 28
Troubleshooting
MID 128 SID 20 Timing Sleeve D7C only Fault Codes

FMI 2
Short circuit to battery voltage, timing sleeve, positive side. Conditions for fault code:
Short circuit to ground, ground side.
Reaction from the EECU: Fault code is set. Red lamp is requested. Injection angle cannot be checked. Output for timing sleeve and rack drive are switched off.
Short circuit to battery voltage on EA9 (EECU checks only when switching on the ignition).
Possible cause:
Short circuit to battery voltage on positive side.
Red lamp lights up. The engine stops or does not start.
FMI 5
Open circuit in the circuit to timing sleeve. Conditions for fault code:
FMI 3
Short circuit to battery voltage, timing sleeve, ground side. Conditions for fault code:
Open circuit between the EECU and the injection pump.
Possible cause:
Open circuit in the wires between the EECU and the injection pump.
Possible cause:
Short circuit between power and ground side. Short circuit to battery voltage on ground side.
Reaction from the EECU: Fault code is set. Red lamp is requested. The timing sleeve cannot be checked. Output for timing sleeve and rack drive are switched off.
Fault code is set. Red lamp is requested. Output for timing sleeve and rack drive are switched off.
FMI 4
Short circuit to ground, timing sleeve, ground side. Conditions for fault code:
Short circuit to ground on EA21.
Possible cause: 162
Group 28
Troubleshooting
FMI 6
Short circuit to ground, timing sleeve positive side. Conditions for fault code:
Fault code is set. Red lamp is requested. Output for timing sleeve and rack drive are switched off.
Possible cause: Short circuit to ground, positive side.
Reaction from the EECU: Fault code is set. Red lamp is requested. Output for timing sleeve and rack drive are switched off.
FMI 11
An unidentiable error has been found.
FMI 7
Needle lift signal available. Incorrect timing sleeve.
Possible cause: Internal fault in the injection pump. Interference in needle lift signal.
FMI 8
Current too high to timing sleeve under long period of time. Conditions for fault code:
Current too high to timing sleeve.
Possible cause: Internal fault in the injection pump. Internal fault in the EECU. 163
Group 28
Troubleshooting
MID 128 SID 20 Timing Sleeve, Check

Supply wire:
4 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 3 / alternate ground Optimal value 40 J-39200
D7C only
NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to: Service Manuals Function Group 37 Electrical Schematics, VNL, VNM
Check of component
Timing sleeve
1 Disconnect the connector to the timing sleeve (7pin connector on the rear of the injection pump). Install breakout box J-38748 to the pump connector end only. Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 3/4 3 / alternate ground 4 / alternate ground Optimal value 1.3
IMPACT
Function Group 2841 Information Type: Diagnostic Fault Codes
J-38748 J-39200
Note that small resistances are difcult to measure. Use the value instead as a standard value for an open in the timing sleeve circuit.

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the timing sleeve (7pin connector on the rear of the injection pump). Take measurements on the wiring harness connector only.
Ground wire:
3 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 4 / alternate ground 164 Optimal value 60 k
J-39200
Group 28
Troubleshooting
MID 128 SID 21 Engine Position Timing Sensor D12B and D12C
The primary function of the engine position sensor (cam sensor) is to provide engine position information to the EECU. As a secondary function, it also provides engine timing (speed) information.
Fault Codes
FMI 3
Short circuit to voltage or permanent loss of signal. Conditions for fault code: cam sensor wheel).
Faulty sensor. Damaged cam sensor wheel.
Engine position signal is not available.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The EECU uses the engine timing sensor signal instead; if this is also incorrect, the engine stops.
Possible cause: Short circuit to voltage, positive wire. Short circuit to voltage, negative wire. Short circuit to ground, positive wire. Open circuit in positive wire. Open circuit in negative wire. An incorrectly installed sensor (incorrect distance to cam sensor wheel). Reversed polarity on the sensor. Faulty sensor. Damaged cam sensor wheel.
Yellow lamp lights up. Difcult to start at the next start (no symptom if the fault code is set when the engine is running).
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The EECU uses engine timing sensor signal instead; if this is also incorrect, the engine stops.
Yellow lamp lights up. Difcult to start at the next start (no symptom if the fault code is set when the engine is running).
FMI 8
Abnormal frequency. Conditions for fault code:
The EECU detects extra pulses on the engine position signal.
Possible cause:
Electrical interference in the engine position signal. Poor insulation or faulty wires. An incorrectly installed sensor (incorrect distance to 165
Group 28
Troubleshooting
MID 128 SID 21 Engine Position Timing Sensor, Check

Supply wire:
D12B and D12C

NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the engine position sensor. Install breakout harness 9998534 to the wiring harness end only.
Check of component
Engine position sensor
1 Disconnect the connector to the engine position sensor. Install breakout harness 9998534 to the sensor harness end only. Measure the resistance with ohmmeter J39200. 9998534 J-39200
9998534
Ignition key must be in the OFF position. Measuring points 1/2 Optimal value 775 - 945
Ground wire:
J-39200
1 / alternate ground 2 / alternate ground
166
Group 28
Troubleshooting
MID 128 SID 21 Needle Lift Sensor

D7C only Needle lift sensor. The needle lift sensor is located on rst the cylinder.
Fault Codes
FMI 2
Intermittent loss of signal or incorrect signal. Conditions for fault code:
Engine speed greater than 450 rpm. Fuel injection is carried out. Missing signal.
Possible cause: Loose connection sensor. Open circuit in one of the wires. Short circuit to ground on any of the wires. Short circuit to battery voltage on any of the wires. Lack of fuel. Faulty sensor. No fuel injection in cylinder 1.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. Timing sleeve (injection angle) is controlled without feedback.
Yellow lamp lights up. Higher fuel consumption than normal.
167
Group 28
Troubleshooting
MID 128 SID 21 Needle Lift Sensor, Check

Supply wire:
D7C only
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the needle lift sensor. Install breakout harness 9998534 to the wiring harness end only.
Check of component
Needle lift sensor
1 Disconnect the connector to the needle lift sensor. Install breakout harness 9998534 to the sensor harness end only. Measure the resistance with ohmmeter J-39200. 9998534 J-39200
9998534
Ground wire:
3 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 2 / alternate ground Optimal value 0.5 J-39200
168
Group 28
Troubleshooting
MID 128 SID 22 Engine Speed Sensor

The primary function of the engine timing sensor (crank sensor) is to provide engine timing (speed) information to the EECU. As a secondary function, it also provides limited engine position information.
Fault Codes
FMI 2
Intermittent loss of signal or incorrect signal. Conditions for fault code: Reaction from the EECU:
Fault code is set. Yellow lamp is requested. The EECU uses the engine position signal instead. If this is also incorrect, the engine stops.
Incorrect engine timing signal.
Possible cause: Electrical interference in the engine timing signal. Loose connection. Poor insulation or faulty wire. An incorrectly installed sensor (incorrect distance to the ywheel). Faulty sensor. Damaged teeth on ywheel.
Yellow lamp lights up. The engine stops if the engine position signal also disappears.
FMI 8
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The EECU uses the engine position signal instead. If this is also incorrect, the engine stops.
The EECU detects extra pulses on the engine timing signal.
Possible cause:
Yellow lamp lights up. The engine stops if the engine position signal also disappears.
Electrical interference. An incorrectly installed sensor. Faulty sensor. Damaged teeth on ywheel.
FMI 3
Signal is not available.
Possible cause: Short circuit to voltage, positive wire. Short circuit to voltage, negative wire. Short circuit to ground, positive wire. Open circuit in positive wire. Open circuit in negative wire. An incorrectly installed sensor. Faulty sensor.
Fault code is set. Yellow lamp is requested. The EECU uses the engine position signal instead. If this is also incorrect, the engine stops.
Yellow lamp lights up. The engine stops if the engine position signal also disappears. 169
Group 28
Troubleshooting
MID 128 SID 22 Engine Speed Sensor, Check

Supply wire:
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the engine timing sensor. Install breakout harness 9998534 to the wiring harness end only.
Check of component
Engine timing sensor
1 Disconnect the connector to the engine timing sensor. Install breakout harness 9998534 to the sensor harness end only. 9998534 J-39200
9998534
Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 1/2 Optimal value 775 - 945
Ground wire:
J-39200
170
Group 28
Troubleshooting
MID 128 SID 23 Rack Actuator D7C only Fault Codes

FMI 2
Short circuit to battery voltage, rack drive positive side. Conditions for fault code:
FMI 4
Short circuit to ground, rack drive ground side. Conditions for fault code:
Possible cause: Short circuit to ground, ground side.
Possible cause:
Short circuit to battery voltage, positive side.
Reaction from the EECU: Fault code is set. Red lamp is requested. EECU connection for power and ground sides is switched off.
FMI 3
Short circuit to battery voltage, rack drive ground side. Conditions for fault code:
FMI 5
Open circuit in the circuit for rack drive. Conditions for fault code:
Fuel injection is requested. Short circuit to battery voltage on EA10.
Possible cause: Short circuit between power and ground side. Short circuit to battery voltage, ground side.
Open circuit in the circuit for rack drive.
Possible cause: Open circuit in wires between EECU and rack drive. Open circuit in rack drive.
Noticeable external symptom: Noticeable external symptom:
171
Group 28
Troubleshooting
FMI 6
Short circuit to ground, rack drive positive side. Conditions for fault code:
The engine stops or does not start.
FMI 8
Current too high to rack drive under long period of time. Conditions for fault code:
Possible cause: Short circuit to ground, positive side.
The current to rack drive is too high for a long period.
Possible cause:
Internal fault in the pump. Internal fault in the EECU.
FMI 7
The rack drive does not move as expected.
FMI 11
Possible cause: Rack drive stuck. Mechanical fault in the pump. Fault in rack drive position sensor.
An unidentiable error has been found.
Red lamp lights up.
172
Group 28
Troubleshooting
MID 128 SID 23 Rack Actuator, Check

Supply wire:
J-39200
D7C only
NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37. Note that small resistances are difcult to measure. Use the value instead as a standard value for an open in the rack drive.
Check of component
Rack drive
1 Disconnect the connector to the rack drive (7pin connector on the rear of the injection pump). Install breakout box J-38748 to the pump connector end only. Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 2/7 1 / alternate ground 2 / alternate ground Optimal value 0.7 J-38748 J-39200

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the rack drive (7pin connector on the rear of the injection pump). Take measurements on the wiring harness connector only.
Ground wire:
J-39200
173
Group 28
Troubleshooting
MID 128 SID 24 Rack Position Sensor D7C only Fault Codes
FMI 2
Incorrect data. Conditions for fault code:
Unreasonable measurement value from rack position sensor.
Possible cause:
Sensor value outside measurement range. Open circuit or short circuit in wires. Internal fault in the pump. Faulty sensor.
Reaction from the EECU: Fault code is set. Red lamp is requested. Output for rack drive is switched off.
Noticeable external symptom: Red lamp lights up. The engine stops or does not start.
FMI 13
Sensor values outside calibration values. Conditions for fault code:

174
Unreasonable measurement value at start-up.
Possible cause: Uncalibrated sensor. Faulty sensor.
Reaction from the EECU: Fault code is set. Red lamp is requested. Output for rack drive actuator is switched off.
Noticeable external symptom: Red lamp lights up. The engine does not start.
Group 28
Troubleshooting
MID 128 SID 24 Rack Position Sensor, Check

Search wire:
J-39200
D7C only
NOTE!
Check all the particular connectors for loose connections as well as for switch resistance and oxidation. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37. Note that small resistances are difcult to measure. Use the value instead as a standard value for an open in the rack position sensor.
Check of component
Rack position sensor
1 Disconnect the connector to the rack drive (7pin connector on the rear of the injection pump). Install breakout box J-38748 to the pump connector end only. Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 5/6 1/6 1, 5, 6 / alternate ground Optimal value 20
(search coil) 20
(reference coil) open circuit J-38748 J-39200

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the rack drive (7pin connector on the rear of the injection pump). Take measurements on the wiring harness connector only.
Reference wire:
J-39200
175
Group 28
Troubleshooting
MID 128 SID 33 Fan Control Fault Codes

FMI 3
FMI 5
Output activated. Short circuit to voltage on EB21.
Output switched off. Open circuit in the circuit for fan control.
Possible cause: Open circuit in the wiring between solenoid valve and EECU. Open circuit in solenoid valve for fan control. Open circuit in supply wire to solenoid valve for fan control. Blown fuse to supply for the fan controls solenoid valve.
Possible cause: Short circuit to battery voltage between solenoid valve and EECU. Short circuit in solenoid valve for fan control.
Noticeable external symptom: Yellow lamp lights up. The fan is in constant operation. Increased fuel consumption.
Fault code is set. Yellow lamp is requested. Output is switched off.
Noticeable external symptom: Yellow lamp lights up. The fan is in constant operation. Increased fuel consumption.
FMI 4

176
Fault code is set. Yellow lamp is requested. Output is switched off.
Noticeable external symptom: Yellow lamp lights up. The fan does not come on. Increased coolant temperature.
Group 28
Troubleshooting
MID 128 SID 33 Fan Control, Check

Check of component
Fan control solenoid valve
1 Disconnect the connector to the fan control solenoid valve. Install breakout harness J-43147 to the solenoid valve harness end only. Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points A/B Optimal value 20 J-43147 J-39200
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the fan control solenoid valve. Install breakout harness J-43147 to the wiring harness end only.
Check of Subsystem
Fan control
J-43147 1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Measuring points EB21 / EB9 EB21 / EB9 ground terminal EB21 with a jumper wire Optimal value B+ (fan on) 0 V (fan off) fan control solenoid valve releases fan J-41132 J-43233 J-39200

3 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points B / alternate ground Optimal value 200 k
J-39200
Supply wire:
4 Measure the voltage with voltmeter J39200. Ignition key must be in the ON position. Measuring points A / alternate ground Optimal value B+ J-39200
177
Group 28
Troubleshooting
MID 128 SID 64 Redundant Engine Speed Sensor D7C only

The redundant engine speed sensor is used as a secondary engine timing (speed) and secondary engine position sensor. Primary engine timing (speed) information is provided by the engine timing (crank) sensor. Primary engine position information is provided by the needle lift sensor.
Fault Codes
FMI 3
FMI 8
Engine position signal is not available.
Possible cause: Short circuit to battery voltage, positive wire. Short circuit to voltage, negative wire. Short circuit to ground, positive wire. Open circuit in positive wire. Open circuit in negative wire. An incorrectly installed sensor (incorrect distance to pump speed sensor wheel). Reversed polarity on the sensor. Faulty sensor. Damaged pump speed sensor wheel.
The EECU detects extra pulses on the engine position signal.
Possible cause:
Electrical interference in the engine position signal. Poor insulation or faulty wires. An incorrectly installed sensor (incorrect distance to pump speed sensor wheel). Faulty sensor. Damaged pump speed sensor wheel.
178
Group 28
Troubleshooting
MID 128 SID 64 Redundant Engine Speed Sensor, Check

Supply wire:
D7C only
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the connector to the engine position sensor. Install breakout harness 9998534 to the wiring harness end only.
Check of component
Redundant engine speed sensor
1 Disconnect the connector to the redundant engine speed sensor. Install breakout harness J-43233 to the sensor harness end only. Measure the resistance with ohmmeter J-39200. J-43233 J-39200
9998534
Ground wire:
J-39200
179
Group 28
Troubleshooting
MID 128 SID 70 Preheater Element 1

Each preheater is equipped with a fuse between the preheating relay and element. The fuse and element are monitored by a sense wire that determines if the circuit is intact.
Fault Codes
FMI 3
Short circuit to battery voltage. Conditions for fault code: Noticeable external symptom:
Preheating relay not activated. The voltage on EB5 is greater than 65% B+.
Yellow lamp lights up. Preheating does not function. White smoke for cold start. Difcult to start in extreme cold.
Possible cause: Short circuit to battery voltage on EB5. Preheating relay constantly on.
FMI 5
Reaction from the EECU: Fault code is set. Yellow lamp is requested. Preheating relay is switched off.
The voltage on EB5 is greater than 5% B+ and less than 65% B+.
Possible cause:
Open circuit in element or wires.
Noticeable external symptom: Yellow lamp lights up. Preheating relay may be constantly activated. High inlet temperature. High current consumption. Discharged battery.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. Output for the pre-heating relay is switched off.
Noticeable external symptom: Yellow lamp lights up. Preheating does not function. Difcult to start in extreme cold.
FMI 4

180
Preheating requested. Short circuit to ground on EB5.
Possible cause: Short circuit to ground on EB5. Preheating relay damaged.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. Output to pre-heating relay is switched off.
Group 28
Troubleshooting
MID 128 SID 70 Preheater Element 1, Check

Special tools: J43233, J-39200, J-41132
Check of Subsystem
Preheating 1, element diagnostics
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Note: Test with Preheat On can be performed only if the EECU has requested pre-heat. Measuring points EB5 / EB9 EB5 / EB9 Optimal value B+ (Preheating on) 0 V (Preheating off) J-41132 J-43233 J-39200
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect sense wire (small solid red wire) at pre-heat relay #1.
Signal wire:
3 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points Sense wire / alternate ground Optimal value 1.4 k
J-39200
Check of component
Preheating 1, element
1 Remove the fuse and support (red plastic part) between the pre-heat relay and the pre-heat element terminal. Ignition key must be in the OFF position. Measure the resistance with ohmmeter J-39200. Measuring points Preheat element terminal / alternate ground Optimal value <1 J-39200
181
Group 28
Troubleshooting
MID 128 SID 71 Preheater Element 2 D12B only

Each preheater is equipped with a fuse between the preheating relay and element. The fuse and element are monitored by a sense wire that determines if the circuit is intact.
Fault Codes
FMI 3
Preheating does not function. White smoke for cold start. Difcult to start in extreme cold.
Preheating relay not activated. The voltage on EB16 is greater than 65% B+.
FMI 5
Possible cause: Short circuit to battery voltage on EB16. Preheating relay constantly on.
The voltage on EB16 is greater than 5% B+ and less than 65% B+.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. The preheating relay is switched off.
Possible cause:
Open circuit in element or wires.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. Output for preheating relay is switched off.
Noticeable external symptom: Yellow lamp lights up. Preheating relay may be constantly on. High inlet temperature. High current consumption. Discharged battery.
Noticeable external symptom: Yellow lamp lights up. Preheating does not function. Difcult to start in extreme cold.
FMI 4

182
Preheating requested. Short circuit to ground on EB16.
Possible cause: Short circuit to ground on EB16. Preheating relay damaged.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. Output to preheating relay is switched off.
Group 28
Troubleshooting
MID 128 SID 71 Preheater Element 2, Check

Check of component
Preheating 2, element
1 Remove the fuse and support (red plastic part) between pre-heat relay #2 and pre-heat element #2 terminal. Ignition key must be in the OFF position. Measure the resistance with ohmmeter J-39200. Measuring points Preheat element terminal / alternate ground Optimal value <1 J-39200
D12B
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the sense wire (small red/white wire) at pre-heat relay #2.
Check of Subsystem
Preheating 2, element diagnostics
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. J-39200 Note: Test with Preheat On can be performed only if the EECU has requested pre-heat. Measuring points EB16 / EB9 EB16 / EB9 Optimal value B+ (Preheating on) 0 V (Preheating off) J-41132 J-43233 J-39200
Signal wire:
3 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points Sense wire / alternate ground Optimal value 1.4 k
183
Group 28
Troubleshooting
MID 128 SID 230 Idle Validation Switch 1 Fault Codes

FMI 3
Accelerator pedal released. The voltage on EB4 exceeds 75% of B+.
Possible cause: Short circuit to battery voltage on wire between EECU and VECU. Error in accelerator pedal.
Noticeable external symptom: Yellow lamp lights up. The "limp home" function does not function.
FMI 4

184
Accelerator pedal pressed down > 50 %. The voltage on EB4 is below 25% of B+.
Possible cause: Short circuit to ground on wire between EECU and VECU. Open circuit in wire between EECU and VECU. Error in accelerator pedal.
Noticeable external symptom: Yellow lamp lights up. The limp home function does not function.
Group 28
Troubleshooting
MID 128 SID 230 Idle Validation Switch 1, Check

NOTE!
Check of Subsystem
Buffered idle validation switch
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EB and the EECU. Connect jumper harness J43233 in series between connector EA and the EECU. Measuring points EB4 / EB9 EB4 / EB9 Optimal value < 4 V (accelerator pedal at idle) > 8 V (accelerator pedal off idle) J-41132 J-43233 J-39200
185
Group 28
Troubleshooting
MID 128 SID 231 SAE J1939 Control Link Fault Codes
FMI 2
Communications link (SAE J1939) does not function. Conditions for fault code:
Information is read/sent instead on the information link (SAE J1587).
No messages are received from the communications link (SAE J1939).
Yellow lamp lights up. Temporary loss of function on:- Cruise ControlPTO.- Pre-heating- Engine brake- Driver position no. 2
Possible cause:
Open circuit in communications link (SAE J1939). Short circuit to voltage on communications link (SAE J1939). Short circuit to ground on communications link (SAE J1939). wires in communications link (SAE J1939) shortcircuited to each other.
FMI 11
Communications link (SAE J1939) does not function internally in EECU at start-up.
Possible cause:
Fault code is set. Yellow lamp is requested. Information is read/sent instead on the information link (SAE J1587).
Internal fault in EECU.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. Information is read/sent instead on the information link (SAE J1587).
Yellow lamp lights up. Noticeable external symptom: Cruise Control does not function. PTO does not function. Preheating relay does not function. Engine brake does not function. Driver position no. 2 does not function.
FMI 9
Communications link (SAE J1939) does not function. Conditions for fault code:
Yellow lamp lights up. Cruise Control does not function. PTO does not function. Preheating does not function. Engine brake does not function. Driver position no. 2 does not function.

186
Communications link (SAE J1939) does not function.
Possible cause: Wires in communications link (SAE J1939) shortcircuited to each other. Temporary malfunction in hardware. Loose connection. Intermittent fault in the wiring.
Group 28
Troubleshooting
FMI 12
Loss of message from the VECU. Conditions for fault code:
The communication between EECU and VECU does not function.
Possible cause:
No contact with VECU.
Reaction from the EECU: Fault code is set. Yellow lamp is requested. Information is read/sent instead on the information link (SAE J1587).
Yellow lamp lights up. Cruise Control does not function. PTO does not function. Preheating does not function. Engine brake does not function. Driver position no. 2 does not function.
187
Group 28
Troubleshooting
MID 128 SID 232 5 Volt DC Supply Fault Codes

FMI 3
Possible cause: Short circuit to battery voltage on the output.
Noticeable external symptom: Yellow lamp lights up. Incorrect values on oil pressure sensor and boost pressure sensor. fault code on oil pressure sensor and boost pressure sensor. Low power output. Oil pressure gauge and boost pressure gauge show 0 in the instrument.
FMI 4

188
Possible cause: Short circuit to ground. Short circuit in sensor. Faulty sensor.
Noticeable external symptom: Yellow lamp lights up. fault code on oil pressure sensor and boost pressure sensor. Oil pressure gauge and boost pressure gauge show 0 in the instrument. Low power output.
Group 28
Troubleshooting
MID 128 SID 232 5 Volt DC Supply, Check

Supply wire:
4 Measure the voltage with voltmeter J39200. Ignition key must be in the ON position. Measuring points 1 / alternate ground Optimal value 5 V (oil pressure/temperature, boost air pressure/temperature, fuel temperature) J-39200
NOTE!

1 Note: An incorrect value (below) can also cause the component to fail; therefore, it is important to check the component if any of the values are incorrect. 2 Disconnect the individual connectors to the fuel temperature sensor (D7C only), boost air temperature/pressure sensor, coolant temperature sensor, and oil temperature/pressure sensor. Install breakout harness 9998534 to the wiring harness end only.
Check of sub-system
5 V supply to sensors
1 Ignition key must be in the ON position. Connect breakout box J-41132 in series between connector EA and the EECU. Connect jumper harness J43233 in series between connector EB and the EECU. Measuring points EA4 / EA5 Optimal value 4.8 - 5.15 V J-41132 J-43233 J39200
9998534
Ground wire:
3 Measure the resistance with ohmmeter J-39200. Ignition key must be in the OFF position. Measuring points 2 / alternate ground 4 / alternate ground Optimal value <1
(coolant temperature) <1
(oil pressure/temperature, boost air pressure/temperature, fuel temperature) J-39200
189
Group 28
Troubleshooting
MID 128 SID 240 Program Memory Fault Codes

FMI 2
Incorrect checksum in program memory. Conditions for fault code:
Incorrect checksum (EECU calculates only at startup).
Possible cause:
Error when programming. Internal fault in the EECU.
FMI 12
Incorrect checksum in program memory. Conditions for fault code:
Incorrect checksum.
Possible cause: Internal fault in the EECU.
Noticeable external symptom: None.
190
Group 28
Troubleshooting
MID 128 SID 250 SAE J1587/1708 Information Link Fault Codes
FMI 12
Internal fault in the EECU. Conditions for fault code:
The information link (SAE J1587) does not function internally in the EECU.
Possible cause:
Internal fault in the EECU.
Noticeable external symptom: Yellow lamp lights up. Information from the EECU is not available on the information link (SAE J1587). The boost pressure gauge shows 0. The oil pressure gauge shows 0. The oil temperature gauge shows 0. The coolant temperature gauge shows 0. The tachometer shows 0.
191
Group 28
Troubleshooting
MID 128 SID 253 Data Set Memory EEPROM Fault Codes
FMI 2
Incorrect checksum in data set memory. Conditions for fault code:
Checksum error.
Possible cause: Internal fault in the EECU. Error when programming.
FMI 12
Incorrect checksum in data set memory. Conditions for fault code:
Checksum error.
192
Group 28
Troubleshooting
MID 128 SID 254 Engine Electronic Control Unit (EECU) Fault Codes
FMI 2
Internal fault in the EECU. Conditions for fault code: Reaction from the EECU:
Fault code is set. Red lamp is requested.
Incorrect self test in the EECU.
FMI 11
FMI 8
FMI 9
193
Group 28
Troubleshooting
FMI 12
FMI 13
Reaction from the EECU: The EECU restarts. fault code can be requested, will not automatically be shown.
The engine falters.
194
Group 28
Troubleshooting
MID 144 VECU

MID 144 Fault Code Table
MID:Message Identication Description. PID:Parameter Identication Description. Error code MID 144-PID 29 Component/Function SecondAccelerator Pedal Position SID:Subsystem Identication Description. FMI:Failure Mode Identier. FMI 3, 4, 5 Section MID 144 PID 29 Second Accelerator Pedal Position Sensor page 198 MID 144 PID 84 Road Speed page 201 MID 144 PID 91 Accelerator Pedal Position page 204 MID 144 PID 152 VECU, Number of Resets page 207 MID 144 PPID 69 Idle Validation Switch page 208 MID 144 PPID 70 Pedal Switches, Supply page 211 MID 144 PPID 71 Cruise Control and Engine Brake, Supply Switch page 215 MID 144 PPID 72 Accelerator Pedal, Supply Sensors page 220 MID 144 PPID 73 Second Accelerator Pedal, Supply Sensors page 223 MID 144 PPID 75 Range Inhibitor, Solenoid Valve Status page 226 MID 144 SID 230 Idle Validation Switch 1 page 229 MID 144 SID 231 SAE J1939 Control Link page 232 MID 144 SID 240 Program Memory page 234 MID 144 SID 243 Cruise Control Set Switch page 235 195
MID 144-PID 84 MID 144-PID 91
Road Speed Accelerator Pedal Position
9 9, 11
MID 144-PID 152
VECU, Number of Resests
MID 144-PPID 69
Idle Validation Switch
9, 11
MID 144-PPID 70
Pedal Switches, Supply
1, 3, 4
MID 144-PPID 71
Cruise Control and Engine Brake, Supply Switch
1, 3, 4
MID 144PPID 72
Accelerator Pedal, Supply Sensors Second Accelerator Pedal, Supply Sensors
3, 4
MID 144PPID 73
3, 4
MID 144PPID 75
Range Inhibitor, Solenoid Valve Status
0, 3, 4, 5
MID 144SID 230
Idle Validation Switch 1
3, 4
MID 144SID 231
SAE J1939 Control Link
0, 3 ,4
Program Memory Crusie Control Set Switch
1 3
Group 28
Troubleshooting
Error code MID 144SID 250
Component/Function SAE J1587/1708 Information Link Data Set Memory EEPROM
FMI 3, 4
Section MID 144 SID 250 SAE J1587/1708 Information Link page 238 MID 144 SID 253 Data Set Memory EEPROM page 240 MID 144 PSID 3 Idle Validation Switch 3 page 241
MID 144SID 253
3, 4
MID144-PSID 3
Idle Validation Switch 3
196
Group 28
Troubleshooting
MID 144 PID 29 Second Accelerator Pedal Position Sensor

Applies only to vehicles with a second accelerator pedal assembly (such as the WX).
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): Second throttle. Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Second throttle position, %
Fault Codes
FMI 3
Abnormally high voltage. Conditions for fault code:
FMI 4
Abnormally low voltage. Conditions for fault code:
If the VECU receives a signal from the sensor that is higher than 4.3 V, the VECU interprets this as a fault and an fault code is set.
If the VECU receives a signal from the sensor that is lower than 0.4 V, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Possible cause:
Open circuit in ground wire. Signal wire short circuited to higher voltage. Faulty second accelerator position sensor. Faulty idle validation switch 3.
Reaction from the VECU: Fault code is set. Yellow lamp is requested.
Open circuit in supply wire. Open circuit in signal wire. Signal wire short-circuited to ground. Faulty second accelerator position sensor. Switch resistance and oxidation.
Noticeable external symptom: Yellow lamp lights up. The engine does not respond when the second accelerator pedal is depressed.
197
Group 28
Troubleshooting
MID 144 PID 29 Second Accelerator Pedal Position Sensor, Check

Other special equipment: J-39200, J-41133, 9998551, J-43340, J-43234
5 Connect a voltmeter to the breakout harness pins and measure the voltage.
Measuring points Pin A / Pin E Expected value 5.4 20% V
J-39200
NOTE! Read off the other fault codes for the VECU. Check the particular connectors during the fault
Signal wire:
6 Turn the ignition key to the OFF position. 7 Connect an ohmmeter to the breakout harness pins and measure the resistance.
Measuring points Pin B / Pin E Expected value 100 20% k
tracing for oxidation and switch resistance. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37.
Appropriate Tests in the VCADS Pro Tool

The following test(s) are useful for closely examining the components function: 271048 Extra accelerator control, switches and sensor, test
J-39200
Wiring harness

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 from the expected value. 1 Disconnect the connector at the second accelerator pedal. Install 5-pin breakout harness J-41133 to the wiring harness end only. J-41133
8 To check the wiring harness, see VNL, VNM Electrical Schematics, Group 37.
Check of component
Second accelerator position sensor Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component. 1 Disconnect the connector at the second accelerator pedal. Install 5-pin breakout harness J-41133 to the second accelerator pedal harness end only. 2 Turn the ignition key to the OFF position. 3 Connect an ohmmeter to the breakout harness pins and measure the resistance.
Measuring points Pin A / Pin E Pin A / Pin B Expected value 4 20% k
4.5 20% k
(accelerator pedal at idle)
Ground wire:
Measuring points Pin E / alternate ground Expected value <1
J-41133
J-39200
J-39200
Supply wire:
4 Turn the ignition key to the ON position. 198
Group 28
Troubleshooting
Check of Subsystem
1 Disconnect the VECU and install adapter J-43234 between the VECU and wiring harness connectors PB/PA. 2 Connect the 60pin breakout box 9998551 (with overlay J-43340) to the adapter. J-43234
Supply wire:
5 Ignition key in ON position. 6 Connect a voltmeter to the 60pin breakout box and measure the voltage. 9998551 J-43340
Measuring points PB26 / PB23 Optimal value 5 20% V
J-39200
Ground wire:
3 Turn the ignition key to the OFF position. 4 Connect an ohmmeter to the 60pin breakout box and measure the resistance.
Measuring points PB23 / Alternate ground Optimal value <1
Signal wire:
7 Turn the ignition key to the ON position. 8 Connect a voltmeter to the 60-pin breakout box and measure the voltage.
Measuring points PB25 / PB23 Expected value 0.5 20% V (accelerator pedal at idle) 3.2 20% V (full acceleration)
J-39200
J-39200
Verication
To verify that the fault has been corrected, use the test in the VCADS Pro tool (see Appropriate Tests in the VCADS Pro Tool page 198).
199
Group 28
Troubleshooting
MID 144 PID 84 Road Speed

The speed signal comes from a sensor on the transmission or as a digital signal if an electronically-controlled transmission is used (i.e. Allison). Diagnostic settings (level 1.5 parameters) are factory programmed based on the transmission type used.
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): Road speed. Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Road speed
Fault Codes
FMI 5
Abnormally low current or open circuit. Conditions for fault code: If the VECU registers a current lower than 90 A on any of the signal wires from the speed sensor the VECU interprets this as a fault and an fault code is set.
FMI 6
Abnormally high current or short circuit. Conditions for fault code:
If the VECU registers a current higher than 140 A on any of the signal wires from the speed sensor, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Possible cause:
Poor contact, sensor connection. Switch resistance and oxidation. Break, signal wire. Fault in sensor.
Signal wire short-circuited to higher voltage. Signal wire short-circuited to ground. Fault in sensor.
Reaction from the VECU: Yellow lamp lights up.
Reaction from the VECU: Yellow lamp lights up.
Noticeable external symptom: No vehicle speed on gauge. No PTO. No cruise control.
Noticeable external symptom: No vehicle speed on gauge. No PTO. No cruise control.
200
Group 28
Troubleshooting
MID 144 PID 84 Road Speed, Check

Other special equipment: J-39200, 9998551, J-43340, J-43234
Wiring Harness
5 To check the wiring harness, refer to VNL, VNM Electrical Schematics, Group 37.
Check of Component Vehicle Speed Sensor

Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component. 1 Disconnect the 2pin vehicle speed sensor connector at the transmission. 2 Turn the ignition key to the OFF position. 3 Connect an ohmmeter to the vehicle speed sensor connector and measure the resistance.
Measuring Expected value* 265 20% 3.4k 20% Transmission points Pin A / Pin B

The following test(s) are useful for closely examining the components function: N/A No test currently available.

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 from the expected value. 1 Disconnect the VECU and install adapter J-43234 to the wiring harness connector PB only. 2 Connect 60pin breakout box 9998511 (with overlay J-43340) to the adapter. J-43234
J-39200
Volvo Fuller Allison HT740 Allison Automatic
3.17k 20%
9998511 J-43340
NO DIAGNOSTICS
Signal wire
3 Turn the ignition key to the OFF position. 4 Connect an ohmmeter to the 60pin breakout box and measure resistance.
Measuring points PB6/PB20 Expected value 265 20% 3.4k 20% Transmission
* Value may vary depending on transmission manufacturer.
J-39200
Volvo Fuller Allison HT740 Allison Automatic
3.17k 20%
NO DIAGNOSTICS
* Value may vary depending on transmission manufacturer.
201
Group 28
Troubleshooting
Check of Subsystem
Signal wire
4 Turn the ignition key to the OFF position.
Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death. 1 Disconnect the VECU and install adapter J-43234 between the VECU and wiring harness connector PA/PB. 2 Connect 60pin breakout box 9998551 (with overlay J-43340) to the adapter. 3
J-43234
5 Connect a voltmeter to the 60pin breakout box and measure the voltage while turning the wheel by hand. The voltage will alternate from positive to negative and will vary with speed. Voltmeter function MIN/MAX may be useful to determine value. Note: The transmission output shaft must be turning.
J-39200
9998551 J-43340
Measuring points
Expected minimum value
Transmission
PB6 / PB20
+0.1 V to -0.1 V +0.1 V to -0.1 V
Volvo
Fuller
Personal injury hazard. Never work under or around a raised vehicle unless it is securely supported on jack stands of adequate rating and the front wheels are securely chocked. Failure to use adequate jack stands and chock the wheels can result in the vehicle falling, which can cause serious injury or death to anyone under or near the vehicle. Chock the front wheels. Release the parking brake and jack up one rear wheel so that it can be turned by hand.
+0.1 V to -0.1 V NO DIAGNOSTICS
Allison HT740 Allison Automatic
Verication
No VCADS Pro tool test is currently available to verify this fault correction.
202
Group 28
Troubleshooting
MID 144 PID 91 Accelerator Pedal Position

Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): Acc. pedal pos. % Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Accelerator pedal position, %
Fault Codes
FMI 3
FMI 4
If the VECU receives a signal from the sensor that is higher than 4.3 V, the VECU interprets this as a fault and an fault code is set.
If the VECU receives a signal from the sensor that is lower than 0.4 V, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Possible cause:
Open circuit in ground wire. Open circuit in supply wire. Signal wire short-circuited to higher voltage. Faulty accelerator position sensor. Faulty idle validation switch 1. Switch resistance and oxidation.
Open circuit in supply wire. Open circuit in signal wire. Signal wire short-circuited to ground. Faulty accelerator position sensor. Switch resistance and oxidation.
Reaction from the VECU: fault code is set. Yellow lamp is requested.
Noticeable external symptom: Yellow lamp lights up. The engine does not respond when the accelerator pedal is depressed.
203
Group 28
Troubleshooting
MID 144 PID 91 Accelerator Pedal Position, Check

Supply Wire:
4 Turn the ignition key to the ON position. 5 Connect a voltmeter to the connector and measure the voltage from pin A to pin E (5pin harness).
J-39200

The following test(s) are useful for closely examining the components function: 271028 Accelerator pedal, switches and sensor, test
Signal Wire:
6 Turn the ignition key to the OFF position. 7 Using an ohmmeter, measure the resistance from pin B to pin E (5pin harness).

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 from the expected value. 1 Disconnect the connector at the accelerator pedal. Install 5-pin breakout harness J-41133 to the wiring harness end only. J-41133
J-39200
Wiring harness
Ground wire:
2 Turn the ignition key to the OFF position. 3 Using ohmmeter J-39200, measure resistance from pin E (5pin harness) to alternate ground.
Check of component accelerator pedal position sensor

J-39200 Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component. 1 Disconnect the connector at the accelerator pedal. Install 5pin breakout harness J-41133 to the accelerator pedal harness only. J-41133
204
Group 28
Troubleshooting
2 Turn the ignition key to the OFF position. 3 Using an ohmmeter, measure the resistance of pin A to pin E, and pin A to pin B.
4.5 20% k
Supply Wire:
5 Turn the ignition key to the ON position. J-39200 6 Using a voltmeter at the 60-pin breakout box, measure the voltage from pin PB10 to PB22.
Measuring points PB10 / PB22 Expected value 5 20% V
J-39200
4 Remove the 5pin breakout harness and reconnect the connector at the accelerator pedal.
Signal Wire:
7 Ignition key in the ON position. 8 Using a voltmeter at the 60-pin breakout box, measure the voltage from pin PB8 to PB22.
Measuring points PB8 / PB22 Expected value 0.5 20% V (accelerator at idle)
Check of Subsystem
1 Disconnect the VECU and install adapter J-43234 between the VECU and wiring harness connectors PA/PB. 2 Connect 60-pin breakout box 9998551 (with overlay J-43340) to the adapter. J-43234
J-39200
9998551 J-43340
3.2 20% V (full acceleration)
Ground Wire
3 Turn the ignition key to the OFF position. 4 Using an ohmmeter at the 60-pin breakout box, measure the resistance between pin PB22 and the alternate ground.
Measuring points PB22 / alternate ground Expected value <1
Verication
J-39200
205
Group 28
Troubleshooting
MID 144 PID 152 VECU, Number of Resets

The software in the VECU contains an internal checking function that restarts the VECU when there is a fault in the execution of the software. PID 152 contains information about how many such restarts that have been made.
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): No. of ECU resets Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Number of ECU resets
Fault Codes
FMI 12
Faulty unit or component. Conditions for fault code:
If an internal software fault occurs an fault code is set.
Possible cause:
The system has been switched off by disconnecting the battery or using a battery master switch instead of switching it off with the ignition key. The system has been restarted due to an internal software fault.
Reaction from the VECU:
Fault code is set. The system is restarted.
206
Group 28
Troubleshooting
MID 144 PPID 69 Idle Validation Switch

The function is used to be able to drive the vehicle in limp home mode if a fault has occurred in the wiring to the engine electronic control unit (EECU).
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): Buff. idle val. sw. Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Buffered idle validation switch
Fault Codes
FMI 4
If the output signal from the buffered idle validation switch deviates from the input signal from idle validation switch 1, the VECU interprets this as a fault and an fault code is set. Note: The fault code is set rst when the accelerator pedal is depressed.
Possible cause:
Short circuit to ground, signal wire
207
Group 28
Troubleshooting
MID 144 PPID 69 Idle Validation Switch, Check

Other special equipment: J-39200, J-41132, J-43234, J-43233, 9998551, J-43340
Wiring harness
Check of component buffered idle validation switch

Note: Faults in the component can be caused by faults in the wiring harness of the VECU. Therefore, a check of the wiring harness should be made before connecting a new component. 1 Disconnect connector (EA and EB) at the EECU. 2 Connect jumper J-43233 between EECUs EA (upper) connector and the wiring harness. 3 Connect the 36-pin breakout box J41132 between the EECUs EB (lower) connector and the wiring harness. 4 Turn the ignition key to the OFF position.


Note: Faults in the wiring harness to the VECU can damage the component. Therefore, a check of the component should be made if any of the measurements deviate from the expected values. 1 Disconnect connector (EA and EB) at the engine electronic control unit (EECU). 2 Connect jumper J-43233 between EECUs EA (upper) connector and the wiring harness. 3 Connect the 36-pin breakout box J41132 between the EECUs EB (lower) connector and the wiring harness.
J-43233
J-41132
J-43233
5 Using ohmmeter J-39200 at the 36 pin breakout box, measure resistance from pin 4 to pin 9.
Measuring points EB4 / EB9 Expected value 2.9 20% k
J-39200
J-41132
Signal Wire:
4 Turn the ignition key to the ON position. 5 Connect voltmeter J-39200 to the 36pin breakout box at pin 4 (buffered idle validation switch) and pin 9 (ground).
Measuring points EB4 / EB9 Expected value 0 V (accelerator pedal at idle) B+ (accelerator pedal above idle)
J-39200
208
Group 28
Troubleshooting
Check of subsystem
1 Disconnect the VECU and install adapter J-43234 between the VECU and wiring harness connectors PA/PB. 2 Connect the 60pin breakout box 9998551 (with overlay J-43340) to the adapter. J-43234
4 Connect voltmeter J-39200 to the 60pin breakout box and measure the voltage.
Measuring points PB17 / PB22 Expected value 0 V (accelerator pedal at idle)
J-39200
9998551 J-43340
B+ (accelerator pedal above idle)
Signal Wire:
3 Turn the ignition key to the ON position.
Verication
209
Group 28
Troubleshooting
MID 144 PPID 70 Pedal Switches, Supply

Voltage supply to pedal switches.
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): Output supply #3 Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Pedal switches supply
Fault Codes
FMI 4
If the VECU registers a voltage lower than 2.5 V on the supply wire, the VECU interprets this as a fault and an fault code is set.
Possible cause:
The supply wire short-circuited to ground. The signal wire for brakes/clutch short-circuited to ground. Signal wire for idle validation switch 1 short-circuited to ground. Faulty switch.
Noticeable external symptom: Yellow lamp lights up. The cruise control function does not work.
210
Group 28
Troubleshooting
MID 144 PPID 70 Pedal Switches, Supply, Check

5 Connect a voltmeter to the breakout harness connector and measure the voltage.
Measuring points Pin D / alternate ground Expected value B+
J-39200
NOTE! Read off the other fault codes for the VECU.
Check the particular connectors during the fault tracing for oxidation and switch resistance. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37.
Supply wire, brake pedal switch:

6 Turn the ignition key to the ON position. 7 Connect a voltmeter to the wiring harness connector and measure the voltage.
Measuring points Expected value B+

The following test(s) are useful for closely examining the components function: 271028 Accelerator pedal, switches and sensor, test Cruise control, switch, test
J-39200
COMMON / alternate ground
275038
Supply wire, clutch pedal switch:

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 from the expected value. 1 Disconnect the connector at the accelerator pedal. Install 5-pin breakout harness J-41133 to the wiring harness end only.
8 Turn the ignition key to the ON position. 9 Connect a voltmeter to the wiring harness connector and measure the voltage.
Measuring points Expected value B+
J-39200
J-41133
COMMON / alternate ground
Signal wire, idle validation switch 1:

10 Turn the ignition key to the OFF position. 11 Connect an ohmmeter to the breakout harness connector and measure the resistance.
Measuring points Pin C / alternate ground Expected value 1.2 20% k
2 Disconnect the connector at the brake pedal switch (two pin, Common-558A wire and Normal Open-567B wire).
J-39200
3 Disconnect the connector at the clutch pedal switch (two pin, Normal Open 571 wire and Common 558B wire).
Supply wire, idle validation switch 1:

Signal wire, brake pedal switch:

12 Turn the ignition key to the OFF position. 211
Group 28
Troubleshooting
13 Connect an ohmmeter to the wiring harness connector and measure the resistance.
Measuring points Normal Open / alternate ground Expected value 1.2 20% k
J-39200
3 Connect an ohmmeter to the connector and measure the resistance.

Measuring points Pin D / Pin C Expected value Open circuit (accelerator pedal at idle) 20-90 tion)
J-39200
(full accelera-
Signal wire, clutch pedal switch:

14 Turn the ignition key to the OFF position. 15 Connect an ohmmeter to the wiring harness connector and measure the resistance.
Measuring points Normal Open / alternate ground Expected value 1.2 20% k
Check of the brake pedal switch:

4 Disconnect the connector at the brake pedal switch (two pin). J-39200 5 Turn the ignition key to the OFF position. 6 Connect an ohmmeter to the switch terminals and measure the resistance.
Measuring points COMMON / Normal Open Expected value <1
J-39200
Wiring harness
(brake pedal not
depressed) open circuit (brake pedal depressed)
Check of component Idle validation switch Brake pedal switch Clutch pedal switch
Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component.
Check of clutch pedal switch:

7 Disconnect the connector at the clutch pedal switch (two pin). 8 Turn the ignition key to the OFF position. 9 Connect an ohmmeter to the switch terminals and measure the resistance.
Measuring points COMMON / Normal Expected value <1
Check of idle validation switch 1:

1 Disconnect the connector at the accelerator pedal. Install 5-pin breakout harness J-41133 to the accelerator pedal harness end only. 2 Turn the ignition key to the OFF position. J-41133
J-39200
(clutch pedal not
Open
depressed) open circuit (clutch pedal depressed)
212
Group 28
Troubleshooting
Check of Subsystem
1 Disconnect the VECU and install adapter J-43234 between the VECU and wiring harness PA/PB. 2 Connect 60pin breakout box 9998551 (with overlay J-43340) to the adapter. J-43234
Signal wire, brake pedal switch:

Measuring points Expected value B+ (brake pedal not depressed) 0 V (brake pedal depressed)
J-39200
9998551 J-43340
Supply wire:
3 Turn the ignition key to the ON position. 4 Connect a voltmeter to the 60-pin breakout boxes and measure the voltage.
Measuring points PB19 / PA12 Expected value B+
PA5 / PA12
Signal wire, clutch pedal switch:

J-39200 9 Turn the ignition key to the ON position. 10 Connect a voltmeter to the 60-pin breakout box and measure the voltage.
Measuring points PA8 / PA12 Expected value B+ (clutch pedal not depressed) 0 V (clutch pedal depressed)
J-39200

Measuring points PA23 / PA12 Expected value 0 V (accelerator pedal at idle) B+ (full acceleration)
J-39200
Verication
To check that the fault has been corrected, use the test in the VCADS Pro tool (see Appropriate Tests in the VCADS Pro Tool page 211).
213
Group 28
Troubleshooting
MID 144 PPID 71 Cruise Control and Engine Brake, Supply Switch
Voltage supply to the cruise control and exhaust brake control switches. Also voltage supply to the idle validation switch 3 (on second accelerator pedal), if so equipped
VCADS Pro Display: Cruise control and retarder switch supply
Fault Codes
FMI 4
Possible cause:
The supply wire short-circuited to ground. The signal wire for the cruise control (SET+/SET/RESUME/ON) short-circuited to ground. The signal wire for the exhaust brake switch (EPG/VEB) short-circuited to ground. The signal wire for the idle validation switch 3 shortcircuited to ground.

214
Noticeable external symptom: Yellow lamp lights up. The cruise control does not function. Exhaust brake does not function. Idle validation switch 3 does not function.
Group 28
Troubleshooting
MID 144 PPID 71 Cruise Control and Engine Brake, Supply Switch, Check
Other special equipment: J-39200, 9998551, J-41133, J-43340, J-43234
Supply wire, cruise control switch:

4 Turn the ignition key to the ON position. 5 Connect a voltmeter to the connector and measure the voltage.
Measuring points Pin A (wire #597A) / alternate ground Expected value B+
J-39200
tracing for oxidation and switch resistance. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37. Note: checks concerning VCB only apply to vehicles equipped with Volvo Compression Brake.
Supply wire, exhaust brake switch:

Measuring points Pin 1 (wire #597B) / alExpected value B+

The following test(s) are useful for closely examining the components function: 275038 253368 271048 Cruise control, switch, test Exhaust brake, switch, test Extra accelerator control, switches and sensor, test
J-39200
ternate ground
Supply wire, idle validation switch 3

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 from the expected value. 1 Disconnect the connector at the switch for the cruise control. Measurements should be taken only on the wiring harness connector end. 2 Disconnect the connector at the switch for the exhaust brake, if the vehicle is equipped with one. Measurements should be taken only on the wiring harness connector end. 3 Disconnect the connector at the second accelerator pedal, if the vehicle is equipped with one. Install the 5pin breakout harness J-41133 to the wiring harness end only.
J-39200
Signal wire, cruise control switch:

J-41133
215
Group 28
Troubleshooting

Measuring points Pin E (wire #563A) / alternate ground Pin G (wire #564A) / alternate ground Pin C (wire #562A) / alternate ground Pin H (wire #565A) / alternate ground Expected value SET+ 1.2 20% k
SET1.2 20% k
ON 1.2 20% k
RESUME 1.2 20% k
J-39200
harness should also therefore be made before connecting a new component.
Check of the switch for the cruise control:

1 Disconnect the connector at the switch for cruise control. Measurements should be taken only on the cruise control switch connector. 2 Turn the ignition key to the OFF position. 3 Connect an ohmmeter to the connector pins and measure the resistance.
Measuring points Pin E / Pin A Expected value open circuit (SET+ inactive)
Signal wire, exhaust brake switch:

12 Turn the ignition key to the OFF position. 13 Connect an ohmmeter to the connector and measure the resistance.
Measuring points Pin 6 (wire #628) / alternate ground Pin 5 (wire #629) / alternate ground Expected value EPG 1.2 20% k
VCB 1.2 20% k
J-39200
J-39200
Pin H / Pin A
<1
(SET+ active)
open circuit (RESUME inactive) <1
(RESUME active)
(ON)
(RESUME active)
(SET- active)
Pin C / Pin A
open circuit (OFF) <1 <1

Pin G / Pin A
<1
open circuit (SET- inactive)
Check of the switch for the exhaust brake:

J-39200 4 Disconnect the connector at the switch for exhaust brake. Measurements should be taken only on the exhaust brake switch pins. 5 Turn the ignition key to the OFF position.
Wiring harness:
Check of component Cruise control switch Exhaust brake switch Idle validation switch 3
Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring 216
Group 28
Troubleshooting
6 Connect an ohmmeter to the switch pins and measure the resistance.

Measuring points Pin 1 / Pin 6 Expected value open circuit (switch OFF) <1 <1
J-39200
9 Connect an ohmmeter to the switch pins and measure the resistance.

Measuring points Pin C / Pin D Expected value open circuit (accelerator at idle)
J-39200
(switch position 1
(switch position 2
- EPG) - VCB) Pin 1 / Pin 5 open circuit (switch OFF) open circuit (switch position 1 - EPG) <1 - VCB)
20-90 tion)
(full accelera-
Check of Subsystem
1 Disconnect the VECU and install adapter J-43234 between the VECU and wiring harness connectors PA/PB. 2 Connect 60pin breakout box 9998551 (with overlay J-43234) to the adapter. J-43234
(switch position 2
Check of the idle validation switch 3:

7 Disconnect the connector at the second accelerator pedal. Install the 5pin breakout harness J-41133 to the accelerator pedal harness end only. 8 Turn the ignition key to the OFF position. J-41133
9998551 J-43234
Supply wire:
Measuring points PB5 / PA12 Expected value B+
J-39200
217
Group 28
Troubleshooting
Signal wire, cruise control switch:

Measuring points PA2 / PA12 Expected value 0 V (SET+ inactive) B+ (SET+ active) PA30 / PA12 0 V (RESUME inactive) B+ (RESUME active) PA3 / PA12 0 V (cruise switch OFF) B+ (cruise switch ON) PA1 / PA12 0 V (SET- inactive) B+ (SET- active)
Signal wire, exhaust brake switch:

Measuring points PA21 / PA12 Expected value 0 V (exhaust brake switch OFF) B+ (exhaust brake switch position 1 EPG) B+ (exhaust brake switch position 2 VCB) PA20 / PA12 0 V (exhaust brake switch OFF ) 0 V (exhaust brake
J-39200
J-39200
PA30 / PA12
B+ (RESUME active) 0 V (RESUME inactive)
switch position 1 EPG) B+ (exhaust brake switch position 2 VCB)

Measuring points PB30 / PA12 Expected value 0 V (accelerator at idle) B+ (full acceleration)
J-39200
Verication
218
Group 28
Troubleshooting
MID 144 PPID 72 Accelerator Pedal, Supply Sensors

The accelerator pedal position sensor is supplied with a reference voltage of 5.0 V. Each change of the accelerator pedal angle controls the input signal to the VECU.
VCADS Pro Display: Accelerator pedal and retarder sensor supply
Fault Codess
FMI 3
FMI 4
If the VECU registers a voltage higher than 5.5 V on the supply wire, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Open circuit in ground wire. Supply wire short-circuited to higher voltage. Open circuit in supply wire. Faulty accelerator position sensor. Switch resistance and oxidation.
Possible cause:
Supply wire short-circuited to ground or lower voltage. Faulty accelerator position sensor.
Noticeable external symptom: Yellow lamp lights up. Engine does not respond when the accelerator pedal is depressed.
219
Group 28
Troubleshooting
MID 144 PPID 72 Accelerator Pedal, Supply Sensors, Check

5 Connect a voltmeter to the connector and measure the voltage from pin A to pin E (5pin harness).
J-39200
Signal wire:
6 Turn the ignition key to the OFF position. 7 Connect an ohmmeter to the 5pin breakout harness and measure the resistance.

J-39200

Wiring harness
Check of component
Accelerator position sensor Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component. 1 Disconnect the connector at the accelerator pedal. Install 5pin breakout harness J-41133 to the accelerator pedal harness end only. 2 Turn the ignition key to the OFF position. 3 Connect an ohmmeter to the breakout harness pins and measure the resistance.
4.5 20% k
Ground wire:
2 Turn the ignition key to the OFF position. 3 Using ohmmeter J-39200, measure the resistance from pin E (5pin harness) to the alternate ground.
J-41133
J-39200
J-39200
Supply wire:
4 Turn the ignition key to the ON position. 220
Group 28
Troubleshooting
Check of Subsystem
Supply wire:
5 Ignition key in ON position. 6 Connect a voltmeter to the 60pin breakout box and measure the voltage from pin PB10 to PB22.
J-39200
9998551 J-43340
Ground wire:
3 Turn the ignition key to the OFF position. 4 Connect an ohmmeter to the 60pin breakout box and measure the resistance between pin PB22 and the alternate ground.
Measuring points PB22/ Alternate ground Optimal value <1
Signal wire:
7 Turn the ignition key to the ON position. J-39200 8 Connect a voltmeter to the 60-pin breakout box and measure the voltage from pin PB8 to PB22.
J-39200
Verication
221
Group 28
Troubleshooting
MID 144 PPID 73 Second Accelerator Pedal, Supply Sensors

The second accelerator pedal position sensor is supplied with a reference voltage of 5.0 V. Each change of the second accelerator pedal angle controls the input signal to the VECU. Note: Applies only to vehicles with a second accelerator pedal assembly (such as the WX).
VCADS Pro Display: Second throttle and wet tank sensor supply
Fault Codes
FMI 3
Abnormally high voltage. Conditions for fault code: Conditions for fault code:
If the VECU registers a voltage higher than 5.5 V on the supply wire, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Possible cause:
Supply wire short-circuited to ground or lower voltage. Faulty second accelerator pedal position sensor.
Open circuit in ground wire. Supply wire short-circuited to higher voltage. Open circuit in supply wire. Faulty second accelerator pedal position sensor. Switch resistance and oxidation.
Noticeable external symptom: Yellow lamp lights up. Engine does not respond when the second accelerator pedal is depressed.
FMI 4
Abnormally low voltage. 222
Group 28
Troubleshooting
MID 144 PPID 73 Second Accelerator Pedal, Supply Sensors, Check

5 Connect a voltmeter to the connector and measure the voltage from pin A to pin E (5pin harness).
J-39200
Signal wire:
6 Turn the ignition key to the OFF position. 7 Connect an ohmmeter to the 5pin breakout harness and measure the resistance.
Measuring points Expected value 100 20% k

The following test(s) are useful for closely examining the components function: 271048 Extra accelerator pedal, switches and sensor, test
J-39200
Pin B / Pin E
Wiring harness

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 from the expected value. 1 Disconnect the connector at the second accelerator pedal. Install 5-pin breakout harness J-41133 to the wiring harness end only. J-41133
Check of component
Second accelerator position sensor Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component. 1 Disconnect the connector at the second accelerator pedal. Install 5pin breakout harness J-41133 to the second accelerator pedal harness end only. 2 Turn the ignition key to the OFF position. 3 Connect an ohmmeter to the breakout harness pins and measure the resistance.
4.5 20% k
Ground wire:
2 Turn the ignition key to the OFF position. 3 Using ohmmeter J-39200, measure the resistance from pin E (5pin harness) to the alternate ground.
J-41133
J-39200
J-39200
Supply wire:
223
Group 28
Troubleshooting
Check of Subsystem
Supply wire:
5 Ignition key in ON position. 6 Connect a voltmeter to the 60pin breakout box and measure the voltage from pin PB26 to PB23.
J-39200
9998551 J-43340
Ground wire:
3 Turn the ignition key to the OFF position. 4 Connect an ohmmeter to the 60pin breakout box and measure the resistance between pin PB23 and the alternate ground.
Measuring points PB23/ Alternate ground Optimal value <1
Signal wire:
7 Turn the ignition key to the ON position. J-39200 8 Connect a voltmeter to the 60-pin breakout box and measure the voltage from pin PB25 to PB23.
J-39200
Verication
224
Group 28
Troubleshooting
MID 144 PPID 75 Range Inhibitor, Solenoid Valve Status

This applies only to vehicles with Volvo transmissions.
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): Range inhibitor Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Range inhibitor solenoid valve
Fault Codes
FMI 3
Abnormally high voltage. Conditions for fault code: the inhibitor is to be released approximately 36 km/h (23 mph). Possible cause:
If the VECU registers a voltage higher than 6.5 V when the function is active, the VECU interprets this as a fault and an fault code is set. Note: The fault code is set rst at the speed when the inhibitor is to engage at approx 40 km/h (25 mph).
The wire between the solenoid valve and the VECU short-circuited to ground. Open circuit, wire between solenoid valve and VECU. Open circuit, supply wire to solenoid valve. Faulty solenoid valve. Switch resistance and oxidation.
Possible cause:
The wire between the solenoid valve and the VECU short-circuited to battery voltage (B+). Faulty solenoid valve.
Noticeable external symptom: Yellow lamp lights up. The range inhibitor is not activated or is constantly active.
Noticeable external symptom: Yellow lamp lights up. The range inhibitor is not activated.
FMI 4
If the VECU registers a voltage lower than 2.3 V when the function is inactive, the VECU interprets this as a fault and an fault code is set. Note: The fault code is set rst at the speed when 225
Group 28
Troubleshooting
MID 144 PPID 75 Range Inhibitor, Solenoid Valve Status, Check

Other special equipment: J-39200, 9998551, J-43340, J-43234, J42472
Supply wire:
4 Turn the ignition key to the ON position. 5 Connect a voltmeter from the breakout harness terminals to the alternate ground and measure the voltage.
Measuring points Terminal 1 (breakout harness) / alternate ground Expected value B+
J-39200

Wiring harness:

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 from the expected value. 1 Disconnect the connector at the range inhibitor solenoid valve. Install 2pin breakout harness J42472 to the wiring harness end only. J42472
Check of Component
Range Inhibitor Solenoid Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component. 1 Disconnect the connector at the range inhibitor solenoid valve. 2 Install 2pin breakout harness J 42472 between the solenoid valve and the wiring harness. 3 Turn the ignition key to the ON position.
J42472
Ground wire:
2 Turn the ignition key to the OFF position. 3 Connect an ohmmeter and measure the resistance.
Measuring points Terminal 2 (breakout harness) / alternate ground Expected value 1.5 20% M
J-39200
226
Group 28
Troubleshooting
4 Ground the #2 breakout pin to an alternate ground. Listen for the range inhibitor valve to click.
Measuring points PB18 / PA12 Connect a jumper wire from PB18 to an alterExpected value B+ Click at range inhibitor solenoid
CAUTION
Accidental grounding of pin #1 may blow a fuse or cause wiring damage.
J-39200
Check of Subsystem
nate ground
Verication
9998551 J-43340
227
Group 28
Troubleshooting
MID 144 SID 230 Idle Validation Switch 1

Idle validation switch 1 is located at the drivers accelerator pedal assembly.
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): Idle valid switch Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Idle validation switch
Fault Codes
FMI 7
Incorrect response from mechanical system. Conditions for fault code:
If the signal from the idle validation switch is not available, with the accelerator position sensor below 13% travel, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Incorrect or faulty idle validation switch. Open circuit in the supply wire. Open circuit in the signal wire. The signal wire short-circuited to ground. The signal wire short-circuited to voltage. Switch resistance or oxidation.
Noticeable external symptom: Yellow lamp lights up. The engine does not respond correctly to acceleration.
228
Group 28
Troubleshooting
MID 144 SID 230 Idle Validation Switch 1, Check

5 Connect an ohmmeter to the breakout harness pins and measure the resistance.
J-39200
NOTE! Read off the other fault codes for the VECU.
Check the particular connectors during the fault tracing for oxidation and switch resistance. For detailed circuit information, refer to VNL, VNM Electrical Schematics, Group 37.
Wiring harness

Check of Component
Idle validation switch 1 Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component. 1 Disconnect the connector at the accelerator pedal. Install 5-pin breakout harness J-41133 to the accelerator pedal harness only. J-41133

Measuring points Pin C / Pin D Expected value open circuit (accelerator at idle) 20-90
Supply wire:
3 Connect a voltmeter to the breakout harness pins and measure the voltage.
(full acceleration)
J-39200
Signal wire:
4 Turn the ignition key to the OFF position. 229
Group 28
Troubleshooting
Check of Subsystem
4 Connect a voltmeter to the 60-pin breakout box and measure the voltage.
Measuring points PA23 / PA12 Expected value 0 V (accelerator at idle) B+ (full acceleration)
J-39200
9998551 J-43340
Verication
Signal wire:
230
Group 28
Troubleshooting
MID 144 SID 231 SAE J1939 Control Link

High-speed digital communication between different electronic control units takes place over the J1939 Control Link; this is used to control vehicle operation. If the J1939 Control Link fails, the J1587/1708 Information Link serves as a back-up control link.
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): SAE J1939 data link Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: SAE J1939 data link
Fault Codes
FMI 2
Intermittent or incorrect data. Conditions for fault code:
Switch resistance and oxidation.
If the VECU does not receive conrmation for the messages on the J1939 Control Link, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Loose connection. Open circuit in J1939 Control Link wire. Switch resistance and oxidation.
FMI 12
Faulty unit or component. Conditions for fault code:
If the expected messages are not available from a control unit on the J1939 Control Link, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Open circuit in J1939 Control Link wire. 231
Group 28
Troubleshooting
MID 144 SID 231 SAE J1939 Control Link, Check

Other special equipment: J-39200
3 Turn the ignition key to the ON position. 4 Using a voltmeter, back probe connector PC (Green 5pin) at connectors PC4 and PC5 with the connector installed in the VECU. Note: This may require the use of voltmeter function MIN/MAX.
Measuring points PC4 / Alternate ground PC5 / Alternate ground PC4 / PC5 Expected value 2-5 V DC 0-3 V DC 0-5 V DC

Check of Subsystem
1 Turn the ignition key to the OFF position. 2 Using an ohmmeter, back probe connector PC (Green 5pin) at connectors PC4 and PC5 with the connector installed in the VECU.
Measuring points PC4 / PC5 Expected value 60 10
Note: The voltage of the control link varies and is dependent on the number of electronic control units and trafc on the control link.
Verication
No VCADS Pro tool test is currently available to verify this fault correction. J-39200
232
Group 28
Troubleshooting
MID 144 SID 240 Program Memory

At startup, a checksum is calculated for the software in the VECUs ash memory. This is compared with the previously stored checksum to verify that the checksum is correct.
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): Program memory Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Programm memory
Fault Codes
FMI 2
If the checksum stored at start up does not agree with the previously stored checksum, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Internal software fault. Faulty memory circuit.
Reaction from the VECU: The VECU 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 in limp home mode.
233
Group 28
Troubleshooting
MID 144 SID 243 Cruise Control Set Switch

Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): CC Set switch Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: CC set switch
Fault Codes
FMI 7
If the VECU receives the signals for SET+ and SETat the same time, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Faulty switch. Signal wire short-circuited to voltage.
Noticeable external symptom: Yellow lamp lights up. The cruise control function does not work. The speed cannot be set.
Note: If the speed has been previously set, it can be resumed.
234
Group 28
Troubleshooting
MID 144 SID 243 Cruise Control Set Switch, Check

Other special equipment: J-39200, 9998551, J-43340, J-43234

Measuring points Wiring harness conExpected value 1.2 20% k
J-39200
nector E / alternate ground
RESUME
Measuring points Expected value 1.2 20% k

The following test(s) are useful for closely examining the components function: 275038 Cruise control, switch, test
J-39200
Wiring harness connector H / alternate ground

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 from the expected value. 1 Disconnect the connector at the switch for the cruise control. Measurements should be taken only on the wiring harness connector.
ON
Measuring points Wiring harness connector C / alternate Expected value 1.2 20% k
J-39200
Supply wire:
Measuring points Wiring harness connector A / alternate ground Expected value B+
ground
SET10 Turn the ignition key to the OFF position. J-39200 11 Connect an ohmmeter to the connector and measure the resistance.
Measuring points Wiring harness connector G / alternate ground Expected value 1.2 20% k
J-39200
Signal wire:
SET+
Wiring harness
12 To check the wiring harness, see VNL, VNM Electrical Schematics, Group 37. 235
Group 28
Troubleshooting
Check of Component
Cruise control set switch Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component. 1 Disconnect the connector at the switch for the cruise control. Measurements should be taken only on the cruise control switch connector. 2 Turn the ignition key to the OFF position. 3 Connect an ohmmeter to the connector and measure the resistance.
Measuring points Cruise control switch connectors E / G Expected value open circuit (SET+ and SET- inactive) open circuit (ON and SET+ active) open circuit (RESUME active and SET+ active) open circuit (ON and SET- active) open circuit (RESUME active and SET- active)
2 Connect 60-pin breakout box 9998551 (with overlay J-43340) to the adapter.
9998551 J-43340
Signal wire:
Measuring points PA1 / PA12 Expected value B+ (OFF and SET- active) 0 V (OFF and SET+
J-39200
J-39200
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 SETactive) 0 V (ON and SET- active) 0 V (RESUME active and SET- active)
Verication Check of Subsystem

1 Disconnect the VECU and install adapter J-43234 between the VECU and wiring harness connectors PA/PB. J-43234 To check that the fault has been corrected, use the test in the VCADS Pro tool (see Appropriate Tests in the VCADS Pro Tool page 235).
236
Group 28
Troubleshooting
MID 144 SID 250 SAE J1587/1708 Information Link

The J1587/1708 Information Link is used to communicate gauge information and diagnostic messages. High-speed digital communication between different electronic control units takes place over the J1939 Control Link; this is used to control vehicle operation. If the J1939 Control Link fails, the J1587/1708 Information Link serves as a back-up control link.
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): SAE J1708 data link Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: SAE J1587/1708 data link
Fault Codes
FMI 2
If the VECU registers incorrect messages on the J1587/1708 Information Link, the VECU interprets this as a fault and an fault code is set.
Possible cause:
Several units are sending at the same time on the J1587/1708 Information Link.
237
Group 28
Troubleshooting
MID 144 SID 250 SAE J1587/1708 Information Link, Check

Special tools: J-39200
2 Using a voltmeter, back the probe connector PC (Green, 5pin) at connectors PC1 and PC2 with the connector installed in the VECU. Note: This may require the use of voltmeter function MIN/MAX.
Measuring points PC1 / Alternate ground PC2 / Alternate ground PC1 / PC2 Expected value 0-5 V DC 0-5 V DC 2-5 V DC
J-39200

Note: The voltage of the information link varies and is dependent on the number of electronic control units and trafc on the information link.
Verication Check of Subsystem

1 Turn the ignition key to the ON position. No VCADS Pro tool test is currently available to verify this fault correction.
238
Group 28
Troubleshooting
MID 144 SID 253 Data Set Memory EEPROM

At start-up, a checksum is calculated for the data set in the VECUs EEPROM memory. This is compared with the previously stored checksum to verify that the data set is correct.
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): Calibration memory Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Calibration memory EEPROM
Fault Codes
FMI 2
Error when programming of the data sets.
Reaction from the VECU: Fault code is set. Red lamp is requested.
If the VECU receives an error in calculating the checksum in the calibration memory, the VECU interprets this as a fault and an fault code is set.
Noticeable external symptom: Red lamp lights up. The vehicle can only be driven in the limp home mode.
Possible cause:
The memory circuit is faulty. Error when programming.
Reaction from the VECU: Fault code is set. Red lamp is requested.
Noticeable external symptom: Red lamp lights up. The vehicle can only be driven in the limp home mode.
FMI 13
Values outside calibration values. Conditions for fault code:
If the VECU receives an error when calculating the checksums for the data sets, the VECU interprets this as a fault and an fault code is set.
Possible cause:
The memory circuit is faulty. 239
Group 28
Troubleshooting
MID 144 PSID 3 Idle Validation Switch 3

This applies only to vehicles with a second accelerator pedal assembly (WX). Note: Idle validation switch 2 is not used in North American applications.
Text Messages In vehicles equipped with diagnostic display, the following message(s) will appear: Instrument Cluster Graphics Display (VN): Idle validation switch 3 Data Link Instrument Cluster (WG, AC, WX): The Data Link instrument cluster graphics display used on WG-, AC-, and WX-series vehicles can display a limited number of text messages. For information, see Data Link Instrumentation, Volvo Service Publication PV776381620SM.
VCADS Pro Display: Idle validation switch 3
Fault Codes
FMI 7
If the signal from the idle validation switch is not available with the accelerator position sensor below 13% travel, the VECU interprets this as a fault and an fault code is set.
Possible cause:

240
Faulty idle validation switch. Open circuit in the supply wire. Open circuit in the signal wire. The signal wire short-circuited to ground. The signal wire short-circuited to voltage. Switch resistance and oxidation.
Noticeable external symptom: Yellow lamp lights up. The engine does not respond correctly when the second accelerator pedal is depressed.
Group 28
Troubleshooting
MID 144 PSID 3 Idle Validation Switch 3, Check

Signal wire:
J-39200

The following test(s) are useful for closely examining the components function: 271048 Extra accelerator control, switches and sensor, test
Wiring harness

Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component. 1 Disconnect the connector at the second accelerator pedal. Install 5-pin breakout harness J-41133 to the wiring harness end only. J-41133
Check of Component
Idle validation switch 3 Note: Faults in the component can be caused by faults in the wiring harness of the VECU. A check of the wiring harness should also therefore be made before connecting a new component. 1 Disconnect the connector at the second accelerator pedal. Install 5-pin breakout harness J-41133 to the accelerator pedal harness end only. 2 Turn the ignition key to the OFF position. 3 Connect an ohmmeter to the connector and measure the resistance. J-41133
Supply wire:
J-39200
J-39200
Measuring points Pin C / Pin D
Expected value open circuit (accelerator at idle) 20-90 tion)
(full accelera-
241
Group 28
Troubleshooting
Check of Subsystem
1 Disconnect the VECU and install adapter J-43234 between the VECU and wiring harness connectors PA/PB. 2 Connect a 60-pin breakout box 9998551 (with overlay J-43340) to the adapter. J-43234
4 Connect a voltmeter to the 60-pin breakout box and measure the voltage.
Measuring points PB30 / PA12 Expected value 0 V (accelerator at idle) B+ (full acceleration)
J-39200
9998551 J-43340
Verication
Signal wire:
242
Group 28
Service Procedures
Service Procedures
2841-03-02-01 Engine ECU, Replacement
Special tools: 9998482
1 Note: Make sure that the parking brake is applied. 2 Disconnect the power with main switch 5
Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death.
T2014052
Remove the bolts for the cooling coil on the control unit. Note: Do not release the fuel lines on the cooling coil. 6 Remove the control units hold-down bolts (4, see previous illustration ) and lift off the control unit. 7 Install the new control unit. Note: Make sure that the framework line is positioned correctly and that the mating surface on the engine block is free from rust. If the control unit is painted where the cooling coil is to be installed: Remove the paint where the cooling coil is in contact with the control unit to ensure maximum cooling. 8 Install the cooling coil on the control unit. 9 Check the clamping force of the terminal in the connector for the control unit by means of gauge 9998482. 10 Install the connector on the control unit. Make sure that the catch locks on the connector. 243
WARNING
Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. Clean up fuel spills immediately. . 3
T2014053
Remove the connector from the control unit by pressing the catch and pushing the handle up. 4 Cut the clamps round the cable harness under the control unit and fold away the connector for the control unit.
9998482
Group 28
Service Procedures
11 Clamp the cables under the control unit. 12 Switch on the power. Note: When starting the engine with cab up, make sure that a gear is not engaged. The parking brake should be applied. 13 Conduct a function check. Check that there are no fault codes in the control unit.
244
Feedback
One of our objectives is that workshop personnel should have access to correct and appropriate service manuals where it concerns fault tracing, repairs and maintenance of Volvo trucks. In order to maintain the high standards of our literature, your opinions and experience when using this manual would be greatly appreciated. If you have any comments or suggestions, make a copy of this page, write down your comments and send them to us, either via telefax or mailing directly to the address listed below.
To Volvo Trucks North America, Inc. Dept. 516 Service Publications 7825 National Service Road P.O. Box 26115 Greensboro, NC 27402-6115 USA Fax (336) 393-3170
From .......................................................................... .......................................................................... .......................................................................... .......................................................................... .......................................................................... .......................................................................... ..........................................................................
Comments/proposals ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ Concerns Service Manual: ...............................................................................................................................
Operation Numbers
2841-03-02-01 Engine ECU, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Volvo Trucks North America, Inc.

P.O. Box 26115, Greensboro, NC 27402-6115
Volvo Trucks Canada, Ltd.

6490 Vipond Drive, Mississauga, Ontario L5T 1W8 http://www.volvotrucks.volvo.com
PV776-TSP144528 (1000) 06.2001 Volvo Trucks North America, Inc., 2001

EECU (D12B and D12C), Breakout Box

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EECU (D12B and D12C), Breakout Box

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TSI

Vehicle Management System Vectro II From 1998

Volvo Trucks North America, Inc.

Order number: PV776-144528

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

Engine Control System Glossary

Fig. 3: EECU voltage check, EB

Fig. 1: EECU with pinouts

Fig. 2: EECU voltage check, EA B+ = battery voltage

Oil temperature sensor, signal

EA4 EA5 EA6 EA7 EA8 EA9

Connection EA10 EA11 EA12 EA13

Ignition key in the ON position

3.0 V (+20 C/68 F)   0.6 V (+85 C/185 F)

0.5V (for cold engines)

Not currently used

Ignition key in the ON position

Coolant level sensor, signal

80% B+ (open) 0 V (closed)

EB22 EB23 EB24

EB25 EB26 EB27 EB28 EB29 EB30 EB31

B+ (pre-heat off) 0 V (pre-heat on)

Normally ON with the ignition key in the ON position.

EB32 EB33 EB34

B+ (EPG off) 0 V (EPG on)

Not currently used

EECU, D7C, with Breakout Box Connected to Wiring Harness Only

Fig. 5: EECU harness checks, EB

Fig. 4: EECU harness checks, EA

Ignition key in the OFF position 1.9 k

Oil temperature sensor, signal

EA3 EA4 EA5 EA6 EA7 EA8

Timing sleeve PWM, +

open circuit (see also EA8)

EA15 / EA28 EA16 / EA17

Ignition key in the OFF position

EA21 / alternate ground

open circuit (see also EA9)

EA29 / EA17 EA30 / EA31 EA31 / EA30

775 - 945 775 - 945

open circuit (open) < 5

open circuit (coolant level normal) <1

open circuit (open)

Ignition key in the OFF position

Fig. 6: EECU voltage check, EA B+ = battery voltage

Fig. 7: EECU voltage check, EB

Ignition key in the ON position

Oil temperature sensor, signal

EA4 EA5 EA6 EA7 EA8 EA9 EA10 EA11 EA12

EA13 EA14 EA15

D12 C EA14 / EA5 0.5 V (for cold engines)

Ignition key in the ON position

EA26 EA27 EA28 EA29 EA30 EA31 EA32 EA33

EA34 EA35 EA36 EB1

Pre-heat sense 1 (if equipped)

EB8 EB9 EB10

Sensor ground EECU ground, EECU ground, -

Connection EB11 EB12 EB13 EB14 EB15 EB16

Ignition key in the ON position

EB11 / EB9 EB12 / EB10

3.0 V (+20 C/68 F) 0.6 V (+85 C/185 F)