Volvo VN 2003 User manual

Service Manual
Trucks
Group 38
Instrument Cluster Fault Codes
MID 140
VN,VHD VERSION2
PV776-TSP161704

Foreword
The descriptions and service procedures contained in this manual are based on de-
signs and methods studies carried out up to March 2003.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary ser-
vice bulletins will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a refer-
ence to an V.S.T. (Volvo Standard Times).
Service procedures which do not include an operation number in the title are for gen-
eral information and no reference is made to an V.S.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to
have the vehicle or component function in the manner intended.
Caution: Indicates an unsafe practice where damage to the product could occur.
Warning: Indicates an unsafe practice where personal injury or severe damage to the
product could occur.
Danger: Indicates an unsafe practice where serious personal injury or death could oc-
cur.
Volvo Trucks North America, Inc.
Greensboro, NC USA
Order number: PV776-TSP161704
© 2003 Volvo Trucks North America, Inc., Greensboro, NC USA
All rights reserved. No part of this publication may be reproduced, stored in
retrieval system, or transmitted in any forms by any means, electronic, me-
chanical, photocopying, recording or otherwise, without the prior written
permission of Volvo Trucks North America, Inc..
USA10483

Contents
Specifications.........................................................................................3
InstrumentCluster,SignalDescriptions................................................3
Tools......................................................................................................13
SpecialTools.......................................................................................13
Otherspecialequipment.....................................................................14
Troubleshooting...................................................................................15
MID140FaultCodeTable..................................................................15
MID140PID77ForwardRearAxleTemperature..............................17
MID140PID77ForwardRearAxleTemperature,Check..................18
MID140PID78RearRearAxleTemperature...................................20
MID140PID78RearRearAxleTemperature,Check.......................21
MID140PID96FuelLevel.................................................................23
MID140PID96FuelLevel,Check....................................................24
MID140PID116ApplicationAirPressure.........................................26
MID140PID116ApplicationAirPressure,Check............................27
MID140PID117AirBrakePressure,Front.......................................29
MID140PID117AirBrakePressure,Front,Check..........................30
MID140PID118AirBrakePressure,Rear.......................................32
MID140PID118AirBrakePressure,Rear,Check...........................33
MID140PID158BatteryVoltage.......................................................35
MID140PID158BatteryVoltage,Check..........................................36
MID140PID171AmbientTemperature.............................................37
MID140PID171AmbientTemperature,Check.................................38
MID140PID177TransmissionOilTemperature................................40
MID140PID177TransmissionOilTemperature,Check...................41
MID140PID178AirSuspensionPressure,Front.............................43
MID140PID178AirSuspensionPressure,Front,Check.................44
MID140PID179AirSuspensionPressure,Rear.............................46
MID140PID179AirSuspensionPressure,Rear,Check.................47
MID140SID231J1939ControlLink.................................................49
MID140SID240ProgramMemory...................................................50
MID140SID250J1587/1708InformationLink..................................51
MID140SID253CalibrationMemory,EEPROM...............................53
MID140PSID7ReferenceResistance.............................................54
MID140PSID200J1939DataLinkInterruption,EngineECU.........55
MID140PSID201J1939DataLinkInterruption,VehicleECU.........56
MID140PSID204J1939DataLinkInterruption,Anti-lockBrake
ECU.....................................................................................................57
MID140PSID210J1939DataLinkInterruption,LightingControl
Module.................................................................................................58
MID140PSID232J1939-3ControlLink...........................................59
Feedback
OperationNumbers
1

2

Group 38 Fault Codes, Instrument Cluster Specifications
Specifications
Instrument Cluster, Signal Descriptions
Connector A (22–pin Green) - with breakout box connected between
the instrument cluster (MID140) and cable harness
Requirements:
•Breakout box 9998699 connected to adapter
9998533 between the instrument cluster and cable
harness. Use extension cable 9990062 if needed.
•Instrument cluster connected.
•Ignition key in the drive position.
•Engine switched off.
•Measuring voltage using the multimeter.
Notes:
V= direct current voltage (V)
Vbat = battery voltage
R= resistance in ohms (
 )
W3005144
Pin Signal type Measurement
points Nominal value Other
A1 Power supply (BAT+) A1 - A2 V ≈Vbat
A2 Ground A2 - ground V≈0V
A3 Ignition supply, (DR or key ON) A3 - A2) V ≈Vbat
A4 Stalk switch, SELECT A4 - A2 V ≈0V
V≈Vbat (SELECT active)
A5 Stalk switch, ESCAPE A5 - A2 V ≈0V
V≈Vbat (ESCAPE active)
A6 Stalk switch, ARROW UP A6 - A2 V ≈0V
V≈Vbat (ARROW UP active)
A7 Stalk switch, ARROW DOWN A7 - A2 V ≈0V
V≈Vbat (ARROW DOWN ac-
tive)
A8 Not used
A9 Not used
A10 SAE J1939-3 High A10-A2 V≈0-5V
A11 Not used
A12 Ref Ground for sensor A12-A2 V≈0V
A13 Not used
3

Group 38 Fault Codes, Instrument Cluster Specifications
Pin Signal type Measurement
points Nominal value Other
A14 Not used
A15 J1939 CAN High A15-A2 V≈3-5V
A16 J1939 CAN Low A16-A2 V≈0-3V
A17 J1587/1708+ A17-A2 V≈0-5V
A18 J1587/1708- A18-A2 V≈0-5V
A19 Not used
A20 Not used
A21 Audible hazard warning (signal
from Lighting Control Module) A21-A2 V≈0V/V
bat (Switching)
A22 J1939-3 Low A22-A2 V≈0-5V
4

Group 38 Fault Codes, Instrument Cluster Specifications
Connector B (30–pin Green) - breakout box connected between the in-
strument cluster (MID140) and cable harness
Requirements:
•Breakout box 9998699 and adapter 9813194 con-
nected between the instrument cluster connector B
and the cable harness. Use extension cable
9990062 if needed.
•Instrument cluster connected.
•Ignition key in the drive position.
•Engine switched off.
•Measuring voltage using the multimeter.
Notes:
V= direct current voltage (V)
Vbat = battery voltage
R= resistance in ohms (
 )
W3005144
Pin Signal type Measurement
points Nominal value Other
B1 Reference Ground (redundant) B1 - ground V ≈0V
B2 Application air pressure sensor,
analog input B2 - ground V ≈0.5 - 5.0 V
B3 Fuel level sensor, analog input B3 - B1 V ≈0-5V
B4 Pyrometer sensor signal, negative
analog input B4 - B5 V ≈5 - 32 mV
B5 Pyrometer sensor signal, positive
analog input B5 - B4 V ≈5 - 32 mV
B6 Rear air suspension pressure
sensor, analog input B6 - ground V ≈0.5 - 5.0 V
B7 Front air suspension pressure
sensor, analog input B7 - ground V ≈0.5 - 5.0 V
B8 Not used
B9 Outside temperature sensor, ana-
log input B9 - B1 V ≈0-5V
B10 Forward rear axle temperature
sensor, analog input B10 - ground V ≈0-5V
B11 Rear rear axle temperature sen-
sor, analog input B11 - ground V ≈0-5V
B12 Transmission oil temperature sen-
sor, analog input B12-B1 V≈0-5V
B13 Front brake air pressure gauge
sensor, analog input B13 - ground V ≈0.5 - 5.0 V
B14 Rear brake air pressure gauge
sensor (analog input) B14 - ground V ≈0.5 - 5.0 V
5

Group 38 Fault Codes, Instrument Cluster Specifications
Pin Signal type Measurement
points Nominal value Other
B15 Not used
B16 Not used
B17 5V supply output, rear air suspen-
sion pressure sensor B17 - ground V ≈5.0 V
B18 5V supply output, application air
pressure sensor B18 - ground V ≈5.0 V
B19 5V supply output, front axle air
pressure sensor B19 - ground V ≈5.0 V
B20 5V supply output for front brake
air pressure sensor B20 - ground V ≈5.0 V
B21 5V supply output, rear brake air
pressure sensor B21 - ground V ≈5.0 V
B22 Not used
B23 Not used
B24 Not used
B25 Not used
B26 Not used
B27 Not used
B28 5th Wheel lock telltale sensor,
digital input B28 - ground V ≈Vbat
B29 Not used
B30 Not used
6

Group 38 Fault Codes, Instrument Cluster Specifications
Connector C (30–pin Blue) - breakout box connected between the in-
strument cluster (MID140) and cable harness
Requirements:
•Breakout box 9998699 and adapter 9998533 con-
nected to connector A and C on the cable harness.
Use extension cable 9990062 if needed.
•Instrument cluster connected.
•Ignition key in the drive position.
•Engine switched off.
•Measuring voltage using the multimeter.
Notes:
V= direct current voltage (V)
Vbat = battery voltage
R= resistance in ohms (
 )
W3005144
Pin Signal type Measurement
points Nominal value Other
C1 Not used
C2 ABS Trailer fault, digital input C2 - A2 V ≈Vbat (Telltale light inactive)
V≈0 V (Telltale light active)
C3 ABS Vehicle fault, digital input C3 - A2 V ≈Vbat (Telltale light inactive)
V≈0 V (Telltale light active)
C4 Traction control system, digital in-
put C4 - A2 V ≈Vbat (Telltale light inactive)
V≈0 V (Telltale light active)
C5 Air filter restriction, digital input C5-A2 V ≈Vbat (Telltale light inactive)
V≈0 V (Telltale light active)
C6 Not used
C7 Battery charging telltale, digital in-
put C7 - A2 V ≈2.2 V (Ignition key in the off position)
V≈Vbat (Alternator charging)
C8 Air dump icon, digital input C8 - A2 V ≈Vbat (Suspension in dump
position)
V≈0 V (Suspension in ride
position)
C9 Not used
C10 Interaxle Differential lock telltale,
digital input C10 - A2 V ≈Vbat (Switch active)
C11 Interwheel Differential lock telltale,
digital input C11 - A2 V ≈Vbat (Differential lock switch active)
C12 Not used
7

Group 38 Fault Codes, Instrument Cluster Specifications
Pin Signal type Measurement
points Nominal value Other
C13 Not used
C14 Not used
C15 Not used
C16 Transmission oil temp telltale digi-
tal input C16 - A2 V ≈0 V (Active signal) V≈Vbat (Inactive signal)
C17 Transmission malfunction icon,
digital input C17 - A2 V ≈0 V (Active signal) V≈Vbat (Inactive signal)
C18 Not used
C19 Not used
C20 Not used
C21 Not used
C22 Not used
C23 Not used
C24 Not used
C25 Not used
C26 Not used
C27 Not used
C28 Not used
C29 Washer fluid level icon, digital in-
put C29 - A2 V ≈0V (Low level) V≈Vbat (Fluid level OK)
C30 Not used
8

Group 38 Fault Codes, Instrument Cluster Specifications
Connector A (22–pin Green) - breakout box connected to cable harness
Requirements:
•Breakout box 9998699 connected to adapter
9998533 towards the cable harness. Use extension
cable 9990062 if needed.
•Instrument cluster disconnected.
•Ignition off.
•Measuring resistance using the multimeter.
Notes:
R= resistance in ohms (
 )
W3005144
Pin Signal type Measurement
points Nominal value Other
A2 Ground A2 - ground R ≈0 
A4 Stalk switch, SELECT A4 - ground R ≈0  (Active)
R≈∞
 (Inactive)
A5 Stalk switch, ESCAPE A5 - ground R ≈0  (Active)
R≈∞
 (Inactive)
A6 Stalk switch, ARROW UP A6 - ground R ≈0  (Active)
R≈∞
 (Inactive)
A7 Stalk switch, ARROW DOWN A7 - ground R ≈0  (Active)
R≈∞
 (Inactive)
9

Group 38 Fault Codes, Instrument Cluster Specifications
Connector B (30–pin Green) - breakout box connected to cable harness
Requirements:
•Breakout box 9998699 and adapter 9813194 con-
nected to cable harness. Use extension cable
9990062 if needed.
•Instrument cluster disconnected.
•Ignition off.
•Measuring resistance using the multimeter.
Notes:
R= resistance in ohms (
 )
W3005144
Pin Signal type Measurement
points Nominal value Other
B1 Reference Ground (redundant) B1 - ground R ≈0 
B3 Fuel level sensor, analog input B3 - B1 R ≈30 - 250 
B9 Outside temperature sensor, ana-
log input B9 - B1 See chart, page 11
B12 Transmission oil temperature sen-
sor, analog input B12-B1 See chart, page 11
10

Group 38 Fault Codes, Instrument Cluster Specifications
Outside Temperature Sensor, Temperature vs. Resistance
W3005183
Transmission Oil Temperature Sensor, Temperature vs. Resistance
W3005184 71

C
(160

F) 82

C
(180

F) 93

C
(200

F) 104

C
(220

F)
Min 235  165  118  85 
Nominal 255  177  125  90 
Max 273
 188  133  95 
11

Group 38 Fault Codes, Instrument Cluster Specifications
Connector C (30–pin Blue) - breakout box connected to cable harness
Requirements:
•Breakout box 9998699 and adapter 9998533 con-
nected to connector A and C on the cable harness.
Use extension cable 9990062 if needed.
•Instrument cluster disconnected.
•Ignition off.
•Measuring resistance using the multimeter.
Notes:
R= resistance in ohms (
 )
W3005144
Pin Signal type Measurement
points Nominal value Other
C3 ABS Vehicle telltale, digital input C3 - A2 R ≈93 k 
C4 Traction control system telltale,
digital input C4 - A2 R ≈∞
 (Inactive)
R≈0
 (Active)
C5 Air filter restriction, digital input C5 - A2 R ≈∞  (Inactive)
R≈0
 (Active)
C11 Interwheel differential lock telltale,
digital input C11 - A2 R ≈∞
 (Diff inactive)
R≈0
 (Diff active)
12

Group 38 Fault Codes, Instrument Cluster Tools
Tools
Special Tools
For special tool and special equipment ordering instructions, see tool information in
group 08.
9998533 Adapter between the instrument
cluster connectors A and C and
breakout box 9998699
T3009536
9813194 Adapter between the instrument
cluster connector B and breakout
box 9998699
9998699 Breakout box 62-pin
9990008 Set with test probes
85104407 Overlay for use with breakout box
9998699 and adapter 9813194
85104406 Overlay for use with breakout box
9998699 and adapter 9998533
13

Group 38 Fault Codes, Instrument Cluster Tools
9990062 Cable Extension for use with
breakout box 9998699 and
adapter 9998533
Other special equipment
For special tool and special equipment ordering instructions, see tool information in
group 08.
J39200 Multimeter
14

Group 38 Fault Codes, Instrument Cluster Troubleshooting
Troubleshooting
MID 140 Fault Code Table
MID:
Message Identification Description (identification of con-
trol unit).
PID:
Parameter Identification Description (identification of pa-
rameter (value)).
PPID:
Proprietary Parameter Identification Description (Volvo
unique identification of parameter (value)).
SID:
Subsystem Identification Description (identification of
component).
PSID:
Proprietary Subsystem Identification Description (Volvo
unique component identification).
FMI:
Failure Mode Identifier (identification of fault type).
Fault code Component / function FMI Reference
PID 77 Forward rear axle temperature 3, 4 “MID 140 PID 77 Forward Rear Axle
Temperature” page 17
PID 78 Rear rear axle temperature 3, 4 “MID 140 PID 78 Rear Rear Axle Tem-
perature” page 20
PID 96 Fuel level 3, 4 “MID 140 PID 96 Fuel Level” page 23
PID 116 Application air pressure 5, 6 “MID 140 PID 116 Application Air Pres-
sure” page 26
PID 117 Air brake pressure, front 5, 6 “MID 140 PID 117 Air Brake Pressure,
Front” page 29
PID 118 Air brake pressure, rear 5, 6 “MID 140 PID 118 Air Brake Pressure,
Rear” page 32
PID 158 Battery voltage 0 “MID 140 PID 158 Battery Voltage”
page 35
PID 171 Ambient temperature 3, 4 “MID 140 PID 171 Ambient Tempera-
ture” page 37
PID 177 Transmission oil temperature 3, 4 “MID 140 PID 177 Transmission Oil
Temperature” page 40
PID 178 Air suspension pressure, front 5, 6 “MID 140 PID 178 Air Suspension
Pressure, Front” page 43
PID 179 Air suspension pressure, rear 5, 6 “MID 140 PID 179 Air Suspension
Pressure, Rear” page 46
SID 231 SAE J1939 Data Link 2 “MID 140 SID 231 J1939 Control Link”
page 49
SID 240 Program memory 2 “MID 140 SID 240 Program Memory”
page 50
SID 250 SAE J1587/J1708 data link 3, 4, 9, 12 “MID 140 SID 250 J1587/1708 Infor-
mation Link” page 51
SID 253 Calibration memory, EEPROM 2 “MID 140 SID 253 Calibration Memory,
EEPROM” page 53
PSID 7 Internal reference resistance 3, 4 “MID 140 PSID 7 Reference Resis-
tance” page 54
PSID 200 Open-circuit, J1939 data link, engine 9 “MID 140 PSID 200 J1939 Data Link
Interruption, Engine ECU” page 55
15

Group 38 Fault Codes, Instrument Cluster Troubleshooting
Fault code Component / function FMI Reference
PSID 201 Open-circuit, J1939 data link, vehicle
control unit 9 “MID 140 PSID 201 J1939 Data Link Interruption, Vehicle ECU” page 56
PSID 204 Open-circuit, J1939 data link, anti-
lock brake control unit 9 “MID 140 PSID 204 J1939 Data Link Interruption, Anti-lock Brake ECU” page
57
PSID 210 Open-circuit J1939 data link, Lighting
control module 9 “MID 140 PSID 210 J1939 Data Link Interruption, Lighting Control Module”
page 58
PSID 232 SAE J1939-3 data link 2 “MID 140 PSID 232 J1939-3 Control
Link” page 59
FMI table
SAE standard
FMI Instrument Cluster Display text SAE text
0 Value too high Data applicable, but above normal operating range.
1 Value too low Data applicable, but below normal operating range.
2 Incorrect data Intermittent or incorrect data.
3 Electrical fault Abnormally high voltage or short-circuit to higher voltage.
4 Electrical fault Abnormally low voltage or short-circuit to lower voltage.
5 Electrical fault Abnormally low current or open-circuit.
6 Electrical fault Abnormally high current or short-circuit to ground.
7 Mechanical fault Incorrect response from the mechanical system.
8 Mechanical or electrical fault Abnormal frequency.
9 Communication fault Abnormal update rate.
10 Mechanical or electrical fault Abnormally high variations.
11 Unknown fault Unidentifiable fault.
12 Component fault Defective unit or component.
13 Incorrect calibration Calibration values outside the limits.
14 Unknown fault Special instructions.
15 Unknown fault Reserved for future use.
16