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Volvo truck diagnostic codes
Drawing II (KDR210)
Nelson Mandela University
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Service Information
Trucks
Group 28
Release 2
Engine Control Module (ECM), Diagnostic Trouble Code
(DTC), Guide
2010 Emissions
Foreword
Order number: PV776- Repl: PV776-
©2012 Volvo Group 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, a division of Volvo Group North America, Inc.
The descriptions and service procedures contained in this manual are based on designs and technical studies carried out through January 2012.
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 deemed to have a significant bearing on this manual, an updated version of this manual will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number, this is a reference to an V.S. (Volvo Standard Times).
Service procedures which do not include an operation number in the title are for general information and no reference is made to an V.S.
Each section of this manual contains specific safety information and warnings which must be reviewed before performing any procedure. If a printed copy of a procedure is made, be sure to also make a printed copy of the safety information and warnings that relate to that procedure. The following levels of observations, cautions and warnings are used in this Service Documentation:
Note:Indicates a procedure, practice, or condition that must be followed in order to have the vehicle or component function in the manner intended.
Caution:Indicates an unsafe practice where damage to the product could occur.
Warning:Indicates an unsafe practice where personal injury or severe damage to the product could occur.
Danger:Indicates an unsafe practice where serious personal injury or death could occur.
VolvoTrucksNorthAmerica, adivisionofVolvoGroupNorthAmerica, Inc.
Greensboro, NC USA
USA
Group 28 Codes (DTCs)
Troubleshooting
Engine Control Module (ECM) Diagnostic Trouble Codes (DTCs)
The manufacturer scan tool is the preferred tool for performing diagnostic work. Contact your local dealer for more information or visit “premiumtechtool”.
Note:The use of a scan tool is necessary to perform diagnostic work as well as clearing of any diagnostic trouble codes (DTCs). DTC(s) can no longer be cleared using the vehicles instrument cluster digital display and stalk switch control.
System Overview
Six electronic control units (ECUs) are used; the engine control module (ECM), instrument control module (ICM), Vehicle Electronic Control Unit (VECU), transmission control module (TCM), the gear selector control module (GSCM) and the aftertreatment control module (ACM). Together, these modules operate and communicate through the SAE J1939 (CAN
- data link to control a variety of engine and vehicle cab functions. The ECM controls such things as fuel timing and delivery, fan operation, engine protection functions, engine brake operation, the exhaust gas recirculation (EGR) valve and the turbocharger nozzle. The VECU controls cruise control functions, accessory relay controls and idle shutdown functions. The ICM primarily displays operational parameters and communicates these to the other ECUs. All have the capability to communicate over the SAE J1587 data link primarily for programming, diagnostics and data reporting.
In addition to their control functions, the modules have on board diagnostic (OBD) capabilities. The OBD is designed to detect faults or abnormal conditions that are not within normal operating parameters. When the system detects a fault or abnormal condition, the fault will be logged in one or both of the modules' memory, the vehicle operator will be advised that a fault has occurred by illumination a malfunction indicator lamp (MIL) and a message in the driver information display, if equipped. The module may initiate the engine shutdown procedure if the system determines that the fault could damage the engine.
In some situations when a fault is detected, the system will enter a "derate" mode. The derate mode allows continued vehicle operation but the system may substitute a sensor or signal value that may result in reduced performance. In some instances, the system will continue to function but engine power may be limited to protect the engine and vehicle. Diagnostic trouble codes (DTCs) logged in the system memory can later be read, to aid in diagnosing the problem using a diagnostic computer or through the instrument cluster display, if equipped. When diagnosing an intermittent DTC or condition, it may be necessary to use a scan tool connected to the Serial Communication Port.
The use of a scan tool is necessary to perform diagnostic work as well as clearing of any diagnostic trouble codes (DTCs). DTC(s) can no longer be cleared using the vehicles instrument cluster digital display and stalk switch control. Additional data and diagnostic tests are available when a scan tool is connected to the Serial Communication Port.
For diagnostic software, contact your local dealer.
The ECM is a microprocessor based controller programmed to perform fuel injection quantity and timing control, diagnostic fault logging, and to broadcast data to other ECUs. The fuel quantity and injection timing to each cylinder is precisely controlled to obtain optimal fuel economy and reduced exhaust emissions in all driving situations.
The ECM controls the operation of the injectors, engine brake solenoid, EGR valve, turbocharger nozzle position, and cooling fan clutch based on inputs from many sensors and information received over the data links from other ECUs.
The VECU and ECM are dependent on each other to perform their specific control functions. In addition to switch and sensor data, the broadcast of data between modules also includes various calculations and conclusions that each module has developed, based on the input information it has received.
Group 28 Codes (DTCs)
####### SAE J1939 FMI Table
FMI SAE Text 0 Data valid but above normal operational range - Most severe level 1 Data valid but below normal operational range - Most severe level
2 Data erratic, intermittent or incorrect 3 Voltage above normal, or shorted to high source 4 Voltage below normal, or shorted to low source 5 Current below normal or open circuit 6 Current above normal or grounded circuit 7 Mechanical system not responding or out of adjustment 8 Abnormal frequency or pulse width or period 9 Abnormal update rate 10 Abnormal rate of change 11 Root cause not known 12 Bad intelligent device or component 13 Out of calibration 14 Special instructions 15 Data valid but above normal operating range - Least severe level 16 Data valid but above normal operating range - Moderately severe level 17 Data valid but below normal operating range - Least severe level 18 Data valid but below normal operating range - Moderately severe level 19 Received network data in error 20 Reserved for SAE assignment 21 Reserved for SAE assignment 22 Reserved for SAE assignment 23 Reserved for SAE assignment 24 Reserved for SAE assignment 25 Reserved for SAE assignment 26 Reserved for SAE assignment 27 Reserved for SAE assignment 28 Reserved for SAE assignment
29 Reserved for SAE assignment 30 Reserved for SAE assignment 31 Condition exists
Group 28 Codes (DTCs)
SAE J1587 Data Link Communication
The electronic control units (ECUs) also communicate on the SAE J1587 data link. These ECUs communicate according to the SAE J1587 standard. The standard has been extended with VOLVO’s own supplement (PPID, PSID). The diagnostic trouble codes (DTCs) set by the ECUs contain information that is described by the following abbreviations.
MID Message Identification Description: Identification of a control module.
PID Parameter Identification Description: Identification of a parameter (value).
PPID Proprietary Parameter Identification Description Volvo: Unique identification of a parameter (value). SID Subsystem Identification Description: Identification of a component. PSID Proprietary Subsystem Identification Description Volvo : Unique identification of a component. FMI Failure Mode Identifier: Identification of fault types.
####### SAE J1587 FMI Table
FMI SAE Text 0 Data valid, but above the normal working range 1 Data valid, but below the normal working range 2 Intermittent or incorrect data 3 Abnormally high voltage or short circuit to higher voltage 4 Abnormally low voltage or short circuit to lower voltage 5 Abnormally low current or open circuit 6 Abnormally high current or short circuit to ground 7 Incorrect response from a mechanical system 8 Abnormal frequency 9 Abnormal update rate 10 Abnormally strong vibrations 11 Non-identifiable fault 12 Faulty module or component 13 Calibration values outside limits 14 Special instructions 15 Reserved for future use
Group 28 Codes (DTCs)
####### SPN 500–
“ECM SPN 558, Accelerator Pedal 1 Idle Validation Switch
- MID 128 SID 230”, page 29
“ECM SPN 626, Intake Air Heater (IAH) Relay – MID 128 PID 45”, page 30
“ECM SPN 628, Program Memory – MID 128 SID 240”, page 30
“ECM SPN 629, Electronic Control Unit (ECU) 1 – MID 128 SID 254”, page 31
“ECM SPN 630, Calibration Memory – MID 128 SID 253”, page 31
“ECM SPN 631, Calibration Module – MID 128 PSID 77/PSID 124”, page 32
“ECM SPN 633, Engine Fuel Actuator 1 Control Command
- MID 128 SID 18”, page 32
“ECM SPN 636, Camshaft Position Sensor (CMP) – MID 128 SID 21”, page 32
“ECM SPN 637, Crankshaft Position Sensor (CKP) – MID 128 SID 22”, page 34
“ECM SPN 639, SAE J1939 Data Link 1 – MID 128 SID 231”, page 35
“ECM SPN 641, Engine Variable Geometry Turbocharger (VGT) Actuator 1 – MID 128 SID 27”, page 35
“ECM SPN 642, Engine Variable Geometry Turbocharger (VGT) Actuator 2 – MID 128 PPID 89”, page 36
“ECM SPN 647, Engine Fan Clutch Output Device Driver – MID 128 SID 33”, page 36
“ECM SPN 651, Engine Injector Cylinder 1 – MID 128 SID 1”, page 37
“ECM SPN 652, Engine Injector Cylinder 2 – MID 128 SID 2”, page 38
“ECM SPN 653, Engine Injector Cylinder 3 – MID 128 SID 3”, page 38
“ECM SPN 654, Engine Injector Cylinder 4 – MID 128 SID 4”, page 39
“ECM SPN 655, Engine Injector Cylinder 5 – MID 128 SID 5”, page 40
“ECM SPN 656, Engine Injector Cylinder 6 – MID 128 SID 6”, page 41
“ECM SPN 677, Engine Starter Motor Relay – MID 128 SID 39”, page 41
“ECM SPN 729, Intake Air Heater (IAH) 1 – MID 128 SID 70”, page 42
“ECM SPN 730, Intake Air Heater (IAH) 2 – MID 128 SID 71”, page 42
“ECM SPN 975, Estimated Percent Fan Speed – (MID 128 PID 26)”, page 43
Group 28 Codes (DTCs)
####### SPN 1000–
“ECM SPN 1072, Engine Compression Brake Output #1 – MID 128 PPID 122”, page 44
“ECM SPN 1127, Engine Turbocharger Intake Manifold Pressure (IMP) – MID 128 PSID 98”, page 45
“ECM SPN 1136, Engine Control Module (ECM) Temperature – MID 128 PPID 55”, page 46
“ECM SPN 1198, Anti–theft Random Number – MID 128 PID 224”, page 46
“ECM SPN 1231, SAE J1939 Data Link 2 – MID 128 PSID 229”, page 47
“ECM SPN 1265, Engine Piston Cooling Oil Pressure Actuator – MID 128 SID 85”, page 47
“ECM SPN 1322, Engine Misfire for Multiple Cylinders – MID 128 PSID 27”, page 48
“ECM SPN 1659, Engine Coolant System Thermostat – MID 128 PSID 109”, page 48
“ECM SPN 1675, Engine Starter Mode – MID 128 SID 39”, page 48
“ECM SPN 1677, Aftertreatment DPF Auxiliary Heater Mode – MID 128 PSID 25”, page 49
“ECM SPN 1761, Aftertreatment Diesel Exhaust Fluid (DEF) Tank Level – PPID 278”, page 49
####### SPN 2000–
“ECM SPN 2003, Transmission Control Module (TCM) Status – MID 128 PSID 205”, page 50
“ECM SPN 2017, Cruise Control Status – MID 128 PID 85”, page 50
“ECM SPN 2029, Invalid or Missing Data from Vehicle ECU
- MID 128 PSID 201”, page 50
“ECM SPN 2629, Engine Turbocharger Compressor Outlet Temperature – MID 128 PID 404”, page 51
“ECM SPN 2659, Engine Exhaust Gas Recirculation (EGR) Mass Flow Rate – MID 128 PPID 35”, page 51
“ECM SPN 2791, Engine Exhaust Gas Recirculation (EGR) Valve Control – MID 128 SID 146”, page 52
“ECM SPN 2836, Battery Potential/Switched Voltage – MID 128 PSID 49”, page 52
Group 28 Codes (DTCs)
####### SPN 4000–
“ECM SPN 4094, NOx Limits Exceeded Due to Insufficient Diesel Exhaust Fluid (DEF) Quality – MID 128 PSID 90”, page 66
“ECM SPN 4095, NOx Limits Exceeded Due to Interrupted Diesel Exhaust Fluid (DEF) Dosing – MID 128 PSID 90”, page 67
“ECM SPN 4334, Afterteatment Diesel Exhaust Fluid (DEF) Dosing Absolute Pressure – MID 128 PPID 273”, page 67
“ECM SPN 4339, Aftertreatment SCR Feedback Control Status – MID 128 PSID 90”, page 68
“ECM SPN 4354, Aftertreatment Diesel Exhaust Fluid (DEF) Line Heater 1 – MID 128 PSID 103”, page 68
“ECM SPN 4356, Aftertreatment Diesel Exhaust Fluid (DEF) Line Heater 3 – MID 128 PSID 102”, page 69
“ECM SPN 4374, Aftertreatment Diesel Exhaust Fluid (DEF) Pump Motor Speed – MID 128 PSID 87”, page 69
“ECM SPN 4375, Aftertreatment Diesel Exhaust Fluid Pump (DEF) Drive Percentage – MID 128 PSID 121”, page 70
“ECM SPN 4376, Aftertreatment Diesel Exhaust Fluid (DEF) Return Valve – MID 128 PSID 105”, page 71
“ECM SPN 4752, Engine Exhaust Gas Recirculation (EGR) Cooler Efficiency – MID 128 SID 282”, page 71
“ECM SPN 4811, Engine Piston Cooling Oil Pressure – MID 128 PPID 8”, page 72
“ECM SPN 4813, Engine Oil Thermostat Bypass Valve Opening – MID 128 PSID 72”, page 72
“ECM SPN 4815, Engine Cooling Fan Thermal Switch Position – MID 128 PPID 333”, page 73
“ECM SPN 5246, Aftertreatment SCR Operator Inducement Severity – MID 128 PSID 46”, page 73
“ECM SPN 5285, Charge Air Cooler (CAC) Temperature – MID 128 PID 52”, page 74
“ECM SPN 5298, Aftertreatment Diesel Oxidation Catalyst (DOC) Conversion Efficiency – MID 128 PSID 99”, page 74
“ECM SPN 5392, Aftertreatment Diesel Exhaust Fluid (DEF) Dosing Valve Loss of Prime – MID 128 PSID 121”, page 74
“ECM SPN 5394, Aftertreatment Diesel Exhaust Fluid (DEF) Dosing Valve – MID 128 PSID 89”, page 75
“ECM SPN 5394, Aftertreatment Diesel Exhaust Fluid (DEF) Dosing Valve – MID 128 PSID 90”, page 76
“ECM SPN 5443, Aftertreatment 1 Hydrocarbon Dosing System – MID 128 PPID 329”, page 76
“ECM SPN 5485, Aftertreatment Diesel Exhaust Fluid (DEF) Pump Orifice – MID 128 PSID 121”, page 77
Group 28 Codes (DTCs)
ECM SPN 84, Wheel-Based Vehicle Speed – MID 128 PID 84
Type of fault:
FMI Description: Fault Condition: Possible Symptoms:
Possible Cause:
FMI 9 • Abnormal update
rate
Missing signal from VECU
Engine derate • SAE J1587 data link vehicle speed message does not exist, (VECU error)
VECU
FMI 10 • Abnormal rate of
change
Vehicle speed deemed inaccurate by VECU
MIL illuminated • Vehicle speed sensor (VSS)
- VECU
FMI 13 • Out of calibration • No vehicle speed
available to VECU
- MIL illuminated • Vehicle speed sensor (VSS)
- VECU
FMI 19 • Received network
data in error
Vehicle speed deemed inaccurate by VECU
MIL illuminated • Vehicle speed sensor (VSS)
- VECU
ECM SPN 91, Accelerator Pedal Position 1 – MID 128 PID 91
Type of fault:
FMI Description: Fault Condition: Possible Symptoms:
Possible Cause:
FMI 9 • Abnormal update
rate
Missing signal from VECU
N/A • SAE J1587 data link pedal information not available
FMI 13 • Out of calibration • Pedal not
connected to VECU
- MIL illuminated • Accelerator pedal sensor fault
FMI 10 • Abnormal rate of
change
Pedal position deemed inaccurate by VECU
MIL illuminated • Accelerator pedal sensor fault
FMI 19 • Received network
data in error
Pedal position deemed inaccurate by VECU
MIL illuminated • Accelerator pedal sensor fault
Group 28 Codes (DTCs)
ECM SPN 98, Engine Oil Level – MID 128 PID 98
Type of fault:
FMI Description: Fault Condition: Possible Symptoms:
Possible Cause:
FMI 1 • Data valid but above
normal operational range
Critically below range
Red Stop or yellow Check lamps illuminated dependent of severity
Low oil level leakage
Critically low oil level
FMI 4 • Voltage below
normal, or shorted to low source
Short Circuit - Positive side
Oil level can not be measured
Engine Oil Level (EOL) sensor failure
Faulty harness
FMI 5 • Current below
normal or open circuit
Short Circuit +, Positive side
Open Circuit +, Positive side
Open Circuit- Negative side
Oil level can not be measured
Engine Oil Level (EOL) sensor failure
Faulty harness
FMI 18 • Data valid but below
normal operating range - Moderately severe level
Moderately below range
Critically below range
Red Stop or yellow Check lamps illuminated dependent of severity
Low oil level leakage
Moderately low oil level
Group 28 Codes (DTCs)
ECM SPN 100, Engine Oil Pressure – MID 128 PID 100
Type of fault:
FMI Description: Fault Condition: Possible Symptoms:
Possible Cause:
FMI 1 • Data valid but below
normal operational range
Critically below range
Engine derate
Low pressure
Red Stop lamp illuminated
Oil leakage
Broken oil pump
Clogged oil system
FMI 3 • Voltage below
normal or shorted low
Short Circuit +, Measuring line
Open Circuit, Ground line
Oil pressure shows 0 in the cluster, engine is running
Yellow Check lamps illuminated
Engine Oil Pressure (EOP) sensor failure
Faulty harness
FMI 5 • Current below
normal or open circuit
Open Circuit +, 5V Supply line
Short Circuit -, Measuring line
Open Circuit, Measuring line
Oil pressure shows 0 in the cluster, engine is running
Yellow Check lamps illuminated
Engine Oil Pressure (EOP) sensor failure
Faulty harness
FMI 13 • Out of Calibration • Sensor indicates a
invalid value
Oil pressure shows 0 in the cluster, engine is running
Engine Oil Pressure (EOP) sensor failure
Faulty harness
FMI 15 • Data valid but above
normal operating range - Least severe level
Sensor indicates a invalid value
Oil pressure shows 0 in the cluster, engine is running
Engine Oil Pressure (EOP) sensor failure
Faulty harness
FMI 17 • Data valid but below
normal operating range - Least severe level
Sensor indicates a invalid value
Oil pressure shows 0 in the cluster, engine is running
Engine Oil Pressure (EOP) sensor failure
Faulty harness
Group 28 Codes (DTCs)
ECM SPN 103, Engine Turbocharger 1 Speed – MID 128 PID 103
Type of fault:
FMI Description: Fault Condition: Possible Symptoms:
Possible Cause:
FMI 0 • Data valid but above
normal operational range
Turbocharger speed is at least 25% greater than the target wheel speed for the measured boost
Engine derate
MIL illuminated
Miss detection
Faulty harness
Faulty harness connector
Turbocharger Speed Sensor
FMI 1 • Data valid but below
normal operational range - Most severe level
Turbocharger speed is at least 25% less than the target wheel speed for the measured boost
Engine derate
MIL illuminated
Miss detection
Faulty harness
Faulty harness connector
Turbocharger Speed Sensor
FMI 9 • Abnormal update
rate
A fault is logged if the Turbocharger Speed Sensor signal is lost
Engine derate
MIL illuminated
Faulty harness
Faulty harness connector
Turbocharger Speed Sensor
FMI 15 • Data valid but above
normal operating range - Least severe level
Turbocharger speed is at least 25% greater than the target wheel speed for the measured boost
Engine derate
MIL illuminated
Miss detection
Faulty harness
Faulty harness connector
Turbocharger Speed Sensor
Group 28 Codes (DTCs)
ECM SPN 105, Engine Intake Manifold 1 Temperature – MID 128 PID 105
Type of fault:
FMI Description: Fault Condition: Possible Symptoms:
Possible Cause:
FMI 0 • Data valid but above
normal operational range - Most severe level
Sensor indicates a invalid value
Engine derate • Poor cooling
- Extreme running conditions
FMI 2 • Data erratic,
intermittent or incorrect
The Intake Manifold Temperature sensor output is too high or too low
Engine derate
MIL illuminated
Poor cooling
Extreme running conditions
Engine Intake Manifold sensor
Faulty harness
Faulty harness connector
Ambient Air Temperature sensor
FMI 4 • Voltage below
normal, or shorted to low source
N/A • Difficult to start in cold climates
Minor cold engine smoke
Engine derate
MIL illuminated
Engine Intake Manifold sensor
Faulty harness
Faulty harness connector
FMI 5 • Current below
normal or open circuit
Possible short to sensor
Difficult to start in cold climates
Engine derate
MIL illuminated
Engine Intake Manifold sensor
Faulty harness
Faulty harness connector
FMI 13 • Out of Calibration • The sensor output
is showing a constant value
Engine derate
Minor cold engine smoke
MIL illuminated
Engine Intake Manifold sensor
Faulty harness
Faulty harness connector
FMI 17 • Data valid but below
normal operating range - Least severe level
The sensor output is showing a constant value
Engine derate
Minor cold engine smoke
MIL illuminated
Engine Intake Manifold sensor
Faulty harness
Faulty harness connector
Volvo truck diagnostic codes
Course: Drawing II (KDR210)
University: Nelson Mandela University
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