Volvo VHD 2003 Service Manual Download Page 5

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Contents

Specifications ......................................................................................... 3

Instrument Cluster, Signal Descriptions ................................................ 3

Tools ...................................................................................................... 13

Special Tools ....................................................................................... 13
Other special equipment ..................................................................... 14

Troubleshooting ................................................................................... 15

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Operation Numbers

Summary of Contents for VHD 2003

Page 1: ...Service Manual Trucks Group 38 Instrument Cluster Fault Codes MID 140 VN VHD VERSION2 PV776 TSP161704 ...

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Page 3: ...ence 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 inj...

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Page 5: ... 158 Battery Voltage Check 36 MID 140 PID 171 Ambient Temperature 37 MID 140 PID 171 Ambient Temperature Check 38 MID 140 PID 177 Transmission Oil Temperature 40 MID 140 PID 177 Transmission Oil Temperature Check 41 MID 140 PID 178 Air Suspension Pressure Front 43 MID 140 PID 178 Air Suspension Pressure Front Check 44 MID 140 PID 179 Air Suspension Pressure Rear 46 MID 140 PID 179 Air Suspension P...

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Page 7: ...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 0 V A3 Ignition supply DR or key ON A3 A2 V Vbat A4 Stalk switch SELECT A4 A2 V 0 V V Vbat SELECT active A5 Stalk switch ESCAPE A5 A2 V 0 V V Vbat ESCAPE active A6...

Page 8: ...alue Other A14 Not used A15 J1939 CAN High A15 A2 V 3 5 V A16 J1939 CAN Low A16 A2 V 0 3 V A17 J1587 1708 A17 A2 V 0 5 V A18 J1587 1708 A18 A2 V 0 5 V A19 Not used A20 Not used A21 Audible hazard warning signal from Lighting Control Module A21 A2 V 0 V Vbat Switching A22 J1939 3 Low A22 A2 V 0 5 V 4 ...

Page 9: ... 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 5 V 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...

Page 10: ...lication 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 gro...

Page 11: ... 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 charg...

Page 12: ...put 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 ...

Page 13: ...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...

Page 14: ... 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 in...

Page 15: ...cations 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 ...

Page 16: ...trument 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 ...

Page 17: ...ter 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 ...

Page 18: ...t 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 ...

Page 19: ... 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 Temp...

Page 20: ...licable 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...

Page 21: ...from the instrument cluster Fault code is stored Yellow lamp requested Noticeable external symptoms Yellow lamp lights up The display shows an icon and the text NO DATA Appropriate check MID 140 PID 77 Forward Rear Axle Temperature Check page 18 FMI 4 Abnormally low voltage or short circuit to lower voltage Conditions for fault code If the instrument cluster registers a voltage of less than 0 5 V ...

Page 22: ...rement at the component s connector to the instrument cluster Note Faults in the instrument cluster cable harness can damage the component Check the component if any of the readings is outside its permitted range Ground cable 1 Requirements The connector for the sensor dis connected Measuring resistance using a multimeter Instrument cluster connected Ignition off Measurement to the instrument clus...

Page 23: ...Ground cable 1 Requirements Breakout box with adapter con nected between instrument cluster connector B and cable harness Measuring resistance using a multimeter Ignition off Instrument cluster connected Measuring points Nominal value Pin B1 ground R 0 Note If the correct value is not achieved remove the voltage from the battery and measure again 9813194 9998699 J39200 Signal cable 2 Requirements ...

Page 24: ...from the instrument cluster Fault code is stored Yellow lamp requested Noticeable external symptoms Yellow lamp lights up The display shows an icon and the text NO DATA Appropriate check MID 140 PID 78 Rear Rear Axle Temperature Check page 21 FMI 4 Abnormally low voltage or short circuit to lower voltage Conditions for fault code If the instrument cluster registers a voltage of less than 0 5 V the...

Page 25: ...ent at the component s connector to the instrument cluster Note Faults in the instrument cluster cable harness can damage the component Check the component if any of the readings is outside its permitted range Ground cable 1 Requirements The connector for the sensor dis connected Measuring resistance using a multimeter Instrument cluster connected Ignition off Measurement to the instrument cluster...

Page 26: ...Ground cable 1 Requirements Breakout box with adapter con nected between instrument cluster connector B and cable harness Measuring resistance using a multimeter Ignition off Instrument cluster connected Measuring points Nominal value Pin B1 ground R 0 Note If the correct value is not achieved remove the voltage from the battery and measure again 9813194 9998699 J39200 Signal cable 2 Requirements ...

Page 27: ...stored Yellow lamp requested Noticeable external symptoms Yellow lamp lights up The fuel level gauge remains permanently at the MIN position The display shows an icon and the text NO DATA Appropriate check MID 140 PID 96 Fuel Level Check page 24 FMI 4 Abnormally low voltage or short circuit to lower voltage Conditions for fault code If the instrument cluster registers a resistance of less than 20 ...

Page 28: ...nstrument cluster cable harness can damage the component Check the component if any of the readings is outside its permitted range Ground cable 1 Requirements The connector for the fuel level sensor B07 disconnected Adapter connected to the instru ment cluster Measuring resistance using a multimeter Instrument cluster connected Ignition off Measurement to the instrument cluster Measuring points No...

Page 29: ...el J39200 Checking sub systems Ground cable 1 Requirements Breakout box with adapter con nected between instrument cluster A03 connector B and cable har ness Measuring resistance using a multimeter Ignition off Instrument cluster connected Measuring points Nominal value Pin B1 ground R 0 Note If the correct value is not achieved remove the voltage from the battery and measure again 9813194 9998699...

Page 30: ...lt code is stored Yellow lamp requested Noticeable external symptoms Yellow lamp lights up The display shows an icon and the text NO DATA Appropriate check MID 140 PID 116 Application Air Pressure Check page 27 FMI 6 Abnormally high current or short circuit to ground Conditions for fault code If the instrument cluster registers a voltage more than 4 7 V the instrument cluster interprets this as a ...

Page 31: ...the instrument cluster Note Faults in the instrument cluster cable harness can damage the component Check the component if any of the readings is outside its permitted range Ground cable 1 Requirements The connector for the application air pressure sensor B06AP dis connected Measuring resistance using a multimeter Instrument cluster connected Ignition off Measurement to the instrument cluster Meas...

Page 32: ... V 5 V Note If the correct value is not achieved remove the voltage from the battery and measure again 9813194 9998699 J39200 Signal cable 2 Requirements Breakout box with adapter con nected between instrument cluster A03 connector B and cable har ness Measuring voltage using the multi meter Ignition key in the drive position Instrument cluster connected Measuring points Nominal value Pins B2 B1 V...

Page 33: ... Fault code is stored Yellow lamp requested Noticeable external symptoms Yellow lamp lights up The display shows an icon and the text NO DATA Appropriate check MID 140 PID 117 Air Brake Pressure Front Check page 30 FMI 6 Abnormally high current or short circuit to ground Conditions for fault code If the instrument cluster registers a voltage more than 4 7 V the instrument cluster interprets this a...

Page 34: ...ts in the instrument cluster cable harness can damage the component Check the component if any of the readings is outside its permitted range Ground cable 1 Requirements The connector for the front brake air pressure sensor B06A dis connected Measuring resistance using a multimeter Instrument cluster connected Ignition off Measurement to the instrument cluster Measuring points Nominal value B06A p...

Page 35: ... V 5 V Note If the correct value is not achieved remove the voltage from the battery and measure again 9813194 9998699 J39200 Signal cable 2 Requirements Breakout box with adapter con nected between instrument cluster A03 connector B and cable har ness Measuring voltage using the multi meter Ignition key in the drive position Instrument cluster connected Measuring points Nominal value Pins B13 B1 ...

Page 36: ... Fault code is stored Yellow lamp requested Noticeable external symptoms Yellow lamp lights up The display shows an icon and the text NO DATA Appropriate check MID 140 PID 118 Air Brake Pressure Rear Check page 33 FMI 6 Abnormally high current or short circuit to ground Conditions for fault code If the instrument cluster registers a voltage more than 4 7 V the instrument cluster interprets this as...

Page 37: ...s in the instrument cluster cable harness can damage the component Check the component if any of the readings is outside its permitted range Ground cable 1 Requirements The connector for the rear brake pressure sensor B06B discon nected Adapter connected to the instru ment cluster Measuring resistance using a multimeter Instrument cluster connected Ignition off Measurement to the instrument cluste...

Page 38: ... V 5 V Note If the correct value is not achieved remove the voltage from the battery and measure again 9813194 9998699 J39200 Signal cable 2 Requirements Breakout box with adapter con nected between instrument cluster A03 connector B and cable har ness Measuring voltage using the multi meter Ignition key in the drive position Instrument cluster connected Measuring points Nominal value Pins B14 B1 ...

Page 39: ...bove normal operating range Conditions for fault code The battery voltage exceeds 15 V for one minute Possible cause Fault in alternator Fast charger connected Reaction from the instrument cluster Fault code is stored Yellow lamp requested Noticeable external symptoms Yellow light and symbol lights up Appropriate check MID 140 PID 158 Battery Voltage Check page 36 35 ...

Page 40: ... cable 1 Requirements Connector A disconnected from the rear of the cluster and con nected to adapter and breakout box Measuring resistance using a multimeter Ignition off Measuring points Nominal value Pins A2 ground R 0 9998699 9998533 J39200 Supply cable 2 Requirements Connector A disconnected from the rear of the cluster and con nected to adapter and breakout box Measuring voltage using the mu...

Page 41: ...ion from the instrument cluster Yellow lamp requested Noticeable external symptoms Yellow lamp lights up The display shows an icon and the text NO DATA Appropriate check MID 140 PID 171 Ambient Temperature Check page 38 FMI 4 Abnormally low voltage or short circuit to lower voltage Conditions for fault code If the instrument cluster registers a resistance of less than 47 the instrument cluster int...

Page 42: ...component if any of the readings is outside its permitted range Ground cable 1 Requirements The connector for the ambient temperature sensor disconnected Measuring resistance using a multimeter Instrument cluster connected Ignition off Measurement to the instrument cluster See page 37 for mea surement points Measuring points Nominal values 2 ground R 0 Note If the correct value is not achieved cut...

Page 43: ...0 C 50 F R 0 5 0 7 k 20 C 68 F R 0 4 0 6 k 25 C 77 F R 200 400 40 C 104 F 1 2 R 100 200 60 C 140 F 9990008 J32900 Checking sub systems Ground lead 1 Requirements Breakout box with adapter con nected between instrument cluster connector B and cable harness Measuring resistance using a multimeter Ignition off Instrument cluster connected Measuring points Nominal value Pin B1 ground R 0 Note If the c...

Page 44: ...from the instrument cluster Fault code is stored Yellow lamp requested Noticeable external symptoms Yellow lamp lights up The display shows an icon and the text NO DATA Appropriate check MID 140 PID 177 Transmission Oil Temperature Check page 41 FMI 4 Abnormally low voltage or short circuit to lower voltage Conditions for fault code If the instrument cluster registers a voltage of less than 0 5 V ...

Page 45: ...nector for the sensor dis connected Measuring resistance using a multimeter Instrument cluster connected Ignition off Measurement to the instrument cluster See page 40 for mea surement points Measuring points Nominal value B ground R 0 Note If the correct value is not achieved disconnect the voltage from the battery J39200 9990008 Signal cable 2 Requirements The connector to the sensor is disconne...

Page 46: ...f the correct value is not achieved remove the voltage from the battery and measure again 9813194 9998699 J39200 Signal cable 2 Requirements Breakout box with adapter con nected between instrument cluster connector B and cable harness Measuring voltage using the multi meter Ignition key in the drive position Instrument cluster connected Measuring points Nominal value Pins B12 B1 Vmax 5 V V min 0 V...

Page 47: ... Fault code is stored Yellow lamp requested Noticeable external symptoms Yellow lamp lights up The display shows an icon and the text NO DATA Appropriate check MID 140 PID 178 Air Suspension Pressure Front Check page 44 FMI 6 Abnormally high current or short circuit to ground Conditions for fault code If the instrument cluster registers a voltage more than 4 7 V the instrument cluster interprets t...

Page 48: ...cluster Note Faults in the instrument cluster cable harness can damage the component Check the component if any of the readings is outside its permitted range Ground cable 1 Requirements The connector for the air suspen sion pressure sensor B56 disconnected Measuring resistance using a multimeter Instrument cluster connected Ignition off Measurement to the instrument cluster Measuring points Nomin...

Page 49: ... 0 V Note If the correct value is not achieved remove the voltage from the battery and measure again 9813194 9998699 J39200 Signal cable 2 Requirements Breakout box with adapter con nected between instrument cluster A03 connector B and cable har ness Measuring voltage using the multi meter Ignition key in the drive position Instrument cluster connected Measuring points Nominal value Pins B7 B1 Vma...

Page 50: ... Fault code is stored Yellow lamp requested Noticeable external symptoms Yellow lamp lights up The display shows an icon and the text NO DATA Appropriate check MID 140 PID 179 Air Suspension Pressure Rear Check page 47 FMI 6 Abnormally high current or short circuit to ground Conditions for fault code If the instrument cluster registers a voltage more than 4 7 V the instrument cluster interprets th...

Page 51: ... in the instrument cluster cable harness can damage the component Check the component if any of the readings is outside its permitted range Ground cable 1 Requirements The connector for the rear air sus pension pressure sensor B58R disconnected Measuring resistance using a multimeter Instrument cluster connected Ignition off Measurement to the instrument cluster Measuring points Nominal value B58R...

Page 52: ...1 V 5 V Note If the correct value is not achieved remove the voltage from the battery and measure again 9813194 9998699 J39200 Signal cable 2 Requirements Breakout box with adapter con nected between instrument cluster A03 connector B and cable har ness Measuring voltage using the multi meter Ignition key in the drive position Instrument cluster connected Measuring points Nominal value Pins B6 B1 ...

Page 53: ... the data link cable between the in strument cluster and other control units Short circuit to ground in the data link cable be tween the instrument cluster and other control units Short circuit to voltage in the data link cable be tween the instrument cluster and other control units Reaction from the instrument cluster Fault code is stored Noticeable external symptoms Lighting functions disappear ...

Page 54: ...t Component A03 instrument cluster Fault code FMI 2 Intermittent or incorrect data Conditions for fault code If the checksum calculated at start up does not agree with the previously saved checksum the in strument cluster interprets this as a fault and a fault code is set Note If a fault code is set reprogram the instru ment cluster Possible cause Software fault Faulty memory circuit Reaction from...

Page 55: ...connect the instrument cluster from the data link by disconnecting the harness connections at the rear Check for active SID250 fault codes in other control units If no other active faults are reported it is likely the instrument cluster has an in ternal problem Replace the instrument cluster If other control units do report an active SID250 fault the problem is likely in the data link wiring or an...

Page 56: ...on link see ser vice information on Data links fault tracing function group 371 FMI 12 Defective unit or component Conditions for fault code If the control units do not send PID 44 to the instru ment cluster but the instrument cluster still has contact with the link echo is available the instru ment cluster interprets this as a fault and a fault code is stored Possible cause One of the control uni...

Page 57: ...eviously stored check sum to check that the data set is correct Component A03 Instrument cluster Fault code FMI 2 Intermittent or incorrect data Conditions for fault code If the content of the memory circuit is faulty the in strument cluster interprets this as a fault and a fault code is set Possible cause Error when programming Fault in the memory circuit Reaction from the instrument cluster Unde...

Page 58: ...reading on the gauges from the directly con nected sensors ambient temperature and fuel level Appropriate check Check all the wiring directly connected to the instru ment cluster FMI 4 Abnormally low voltage or short circuit to lower voltage Conditions for fault code If the instrument cluster registers a resistance of less than 22 5 the instrument cluster interprets this as a fault and a fault cod...

Page 59: ...ate rate Conditions for fault code If the instrument cluster does not receive the mes sage from the engine control unit via the J1939 control data link within a specific time period the in strument cluster interprets this as a communication fault from the engine control unit and a fault code is stored Possible cause Fault in the J1939 data link between the instrument cluster and the engine control...

Page 60: ...s for fault code If the instrument does not receive the message from the vehicle control unit via the J1939 control data link within a specific time period the instrument cluster interprets this as a communication fault from the vehicle control unit and a fault code is stored Possible cause Fault in the J1939 data link between the instrument cluster and the vehicle control unit Reaction from the i...

Page 61: ...te rate Conditions for fault code If the instrument cluster does not receive the mes sage from the Anti lock brake ABS control unit via the J1939 control data link within a specific time pe riod the instrument cluster interprets this as a communication fault from the engine control unit and a fault code is stored Possible cause Fault in the J1939 data link between the instrument cluster and the AB...

Page 62: ...ditions for fault code If the instrument cluster does not receive the mes sage from the external lighting control unit via the J1939 control data link within a specific time period the instrument cluster interprets this as a communi cation fault from the external lighting control unit and a fault code is stored Possible cause Fault in the external lighting control unit Reaction from the instrument...

Page 63: ...Open circuit in the data link cable between the in strument cluster and other control unit SWM Short circuit to ground in the data link cable between the instrument cluster and other control unit SWM Short circuit to voltage in the data link cable between the instrument cluster and other control unit SWM Reaction from the instrument cluster Fault code is stored Noticeable external symptoms Radio f...

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Page 65: ...ur 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 39...

Page 66: ...k 41 3811 21 02 08 MID 140 PID 158 Battery Voltage Check 36 3811 21 02 10 MID 140 PID 77 Forward Rear Axle Temperature Check 18 3811 21 02 13 MID 140 PID 116 Application Air Pressure Check 27 3811 21 02 14 MID 140 PID 117 Air Brake Pressure Front Check 30 3811 21 02 15 MID 140 PID 118 Air Brake Pressure Rear Check 33 3811 21 02 16 MID 140 PID 178 Air Suspension Pressure Front Check 44 3811 21 02 1...

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Page 68: ...th 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 TSP161704 500 3 2003 Volvo Trucks North America Inc 2003 ...

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