Service Manual

Buses
Group 93
Release 01
MID 249 BBM
Multiplex electrical system Version 2

20 013143
 Foreword
The descriptions and directions in this manual have been based on design
and method studies up to and including January 2004.

The products are under continual development. Values and repair

methods may therefore differ on vehicles and components manufactured
after this date.

This service information uses the following observation and warning levels:

Note! indicates a situation, use or circumstance that should

be emphasised.

Important! indicates a situation, use or circumstance that is

important to be aware of in order to avoid personal injury
or damage to the product.

Caution! indicates a potentially dangerous situation that unless it is

avoided may lead to minor or moderate personal injury or
damage to the product.

Warning! indicates a potentially dangerous situation that unless it is

avoided may lead to lethal injury, serious personal injury
or damage to the product.

Danger! indicates an apparent dangerous situation that unless it is

avoided may lead to lethal injury or severe personal injury.

Order number: 20 013143

© 2004 Volvo Bus Corporation, Göteborg, Sweden

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 Bus Corporation.
ENG14928
 Contents
General .................................................................................................... 2
Multiplexed electrical system ................................................................. 2

Specifications ......................................................................................... 3
Bodybuilder module, BBM ..................................................................... 3

Tools ........................................................................................................ 4
Special tools, BBM ................................................................................. 4
Design and Function ............................................................................. 5
Signal description, BBM ......................................................................... 7

Malfunction ............................................................................................. 8
MID 249 Fault code table, BBM ............................................................. 8
Fault codes, fault tracing ........................................................................ 9
MID 249 SID 226 Short circuit, neutral gear ........................................ 12
MID 249 SID 231 J1939 Control link BBM ........................................... 13
MID 249 SID 250 SAE J1708 Information link ..................................... 14
MID 249 SID 253 Calibration memory EEPROM ................................ 15
MID 249 PSID 101 Starter inhibitor ..................................................... 16
MID 249 PSID 102 Emergency switch ................................................. 17
MID 249 PSID 105 Sensor, Engine Hatch ........................................... 18
MID 249 PSID 106 D-bus .................................................................... 19

1
Group 28 MID 249 BBM General

General
Multiplexed electrical system
The multiplex electrical system BEA II differs from
earlier electrical systems, since BIC and ECS have
been replaced by a new generation of control units. In
addition, BBM, who’s purpose is to communicate between
bodywork and chassis, has been added.

MID 249 BBM

The body-builder module or BBM is an extension of the
vehicle control unit, VECU and is intended for bodywork.
The bodybuilder module is part of a complete unit
together with the vehicle control unit and is located in the
electrical centre. There are two 30-pin connectors on the
body builder module for the chassis and the bodywork.

2
Group 28 MID 249 BBM Specifications

Specifications
Bodybuilder module, BBM
Marking 1 Part number

2 Designation

3 Supplier’s identity

4 Country of manufacture

5 Supplier part number

6 Version

7 Bar code

BxDxH 126 x 110 x 75 mm T3017332

Operating temperature -40 C to +70 C

Storage temperature -40 C to +85 C

Supply voltage 24 V

Data links 1 Control link SAE link J1939:

250 kbit/s
1 information link SAE link
J1587/J1708: 9.6 kbit/s

Inputs 31

Outputs 10

3
Group 28 MID 249 BBM Tools

Tools
Special tools, BBM

9998699 9998533 9998534

Adapter for A. Blue connector to
Breakout box, 62-pin orange connector block Adapter for component.

9812519 9813194
Adapter for B. Green connector to
Multimeter white connector block

4
Group 28 MID 249 BBM Design and Function

Design and Function

Design
The connector pins on the bodybuilder module (BBM)
have different electrical properties. The abbreviations
used for the different signal types are described below.
HDI High Digital Input

LDI Low Digital Input

GDI General Digital Input (HDI/LDI,

selectable)

HDO High Digital Output

LDO Low Digital Output

HTDI High Digital Input True

LTDI Low Digital Input True

HLDI High Low Digital Input

AI Analogue Input

AO Analogue Output

RES Resistance

The signal types HDI, LDI, HDO and LDO have different
logic and structure in the control unit. The signals
have therefore different properties; see table. Note
that the limits for the different signal characteristics are
programmable and can therefore differ slightly between
the different pins. Signal types AO, AI and PWM have
fully individual programmable properties and will therefore
not be covered in more detail here.

Limits, % of Ubat HDI LDI HDO LDO HTDI LTDI HLDI

1
U > 75% True Error True False True False
25% < U < 75% False False Error Error Error Error Error
2
U < 25% Error True False True False True
1
True or False, the logic is programmable.
2
False or True, the logic is programmable.

DI H = Digital signal with high activation.

If the voltage is >7.7 V the control unit interprets the
signal as active, and if the voltage is <3.5 V the signal
is interpreted as inactive.

DI L = Digital signal with low activation.

If the voltage is <3,5 V the control unit interprets the
signal as active, and if the voltage is >7.7 V the signal
is interpreted as inactive.

5
Group 28 MID 249 BBM Design and Function

List of parameters
In the following table, all available customer and vehicle
parameters are listed. To program vehicle parameters
requires connection to Volvo (VDA), which is symbolised
by a connection symbol in the column farthest to the
left. The vehicle parameters are either accessories or
functions which are governed by legal requirements.
Customer parameters, on the other hand, can be
programmed without connecting to the VDA.

Vehicle control unit

VDA ID Designation Description Limits Unit
CUT Speed hysteresis Lower level of speed 0 — 250 km/h
hysteresis
CUU Speed hysteresis Higher level of speed 0 — 250 km/h
hysteresis
DFI Sensor, engine hatch Activation of sensor for Yes/No
engine hatch
DFJ Engine running Rpm when engine is running 0 — 2550 revs/min
DHG Power off, timer The power is turned off 0 — 512 sec
seconds after the engine of
turned off
DHH Power on, timer The engine must have 0 — 512 sec
power on seconds before it
is started
DHI Power on at engine speed The parameter must be 0 — 2550 revs/min
running before “Power on,
timer” can be activated
DHJ Power on, power At the factory setting, 27 V, 0 — 37,5 V
the power should be on
DHK Power off, power At the factory setting, 23 V, 0 — 37.5 V
the power should be off
DHN Speed hysteresis Lower level of speed 0 — 250 km/h
hysteresis
DHO Speed hysteresis Higher level of speed 0 — 250 km/h
hysteresis
EA Type of gearbox Identifies which type of
gearbox the vehicle has
GQ Engine, speed limitation States the engines max 500 — 2550 revs/min
speed
GR Engine, torque limitation 1 States the engine’s max 0–100 %
torque, value 1
GS Engine, torque limitation 2 States the engine’s max 0–100 %
torque, value 2
PO Articulated vehicle States whether the bus is Yes/No
articulated or not
PSZ Articulated vehicle States whether the bus Yes/No
is a pushing or dragging
articulated bus
SC Bodywork multiplex States if the bus is equipped Yes/No
with bodywork multiplex or
not
VZ ECS, ramp Yes/No

6
Group 28 MID 249 BBM Design and Function

Signal description, BBM

Connector block A
Connector block B
Pin no. Function
Pin no. Function
A1 Ignition (+15)
B1 Status, door brake
A2 Button, engine shut-off
B3 Low priority
A4 Emergency switch
B8 Sensor, brake pressure third braking
A6 Inhibit ECS circuit
A7 Inhibit start B10 Sensor, supply brake pressure third
A8 Bodywork connector block 4:1 braking circuit

A12 Ground connection B11 Switch, parking brake

A13 Power supply, (+30) B12 Switch, jack-knife warning critical

angle articulated bus
A14 Battery main switch
B13 Switch, jack-knife alarm critical angle
A15 D-bus, high articulated bus
A16 D-bus, low B15 Relay, power supply (+30)
A17 Bodywork connector block 4:2 B16 Relay,
A18 Bodywork connector block 4:3 B21 Braking request, sensor turn table
A19 Bodywork connector block 4:4 B22 Sensor, ground brake pressure third
braking circuit
A20 Bodywork connector block 4:5
B29 Switch, engine hatch
A21 Bodywork connector block 1:3
B30 Feed, relay bodywork
A23 Sensor, fire alarm engine
Body connector block
compartment
Bodywork connector block, switch
A24 Engine torque 2 baggage hold hatch
A25 Neutral gear
Connector block C
A26 Start inhibit
Pin no. Function
A27 Hydraulic pressure
C1 Control link SAE J1939, high
A28 Engine torque 1
C2 Control link SAE J1939, low
A29 Start button, rear of engine
compartment C4 Information link SAE J1587/1708, low
C5 Information link SAE J1587/1708,
high

7
Group 28 MID 249 BBM Malfunction

Malfunction
MID 249 Fault code table, BBM
• “Bodybuilder module, BBM” page 3
• “Special tools, BBM” page 4
• “Design” page 5
• “Signal description, BBM” page 7
• “Fault codes, fault tracing” page 9

Fault code table

SID
“MID 249 SID 226 Short circuit, neutral gear” page 12
“MID 249 SID 231 J1939 Control link BBM” page 13
“MID 249 SID 250 SAE J1708 Information link” page 14
“MID 249 SID 253 Calibration memory EEPROM” page 15

PSID
“MID 249 PSID 101 Starter inhibitor” page 16
“MID 249 PSID 102 Emergency switch” page 17
“MID 249 PSID 105 Sensor, Engine Hatch” page 18
“MID 249 PSID 106 D-bus” page 19

8
Group 28 MID 249 BBM Malfunction

Fault codes, fault tracing

The control units on the information link communicate (PPID, PSID). The fault codes set by the control units
according to the SAE J1587 standard. The standard contain information that is described by the following
has been extended with Volvo’s own supplement abbreviations.

MID Message Identification Description – PSID Proprietary Subsystem Identification

identification of a control unit. Description – Volvo unique identification
of a component.
PID Parameter Identification Description –
identification of a parameter (value). FMI Failure Mode Identifier – identification
of fault types.
PPID Proprietary Parameter Identification
Description – Volvo unique identification
of a parameter (value).
SID Subsystem Identification Description –
identification of a component.

FMI table
FMI Display text SAE-text
0 Value too high Data valid, but above the normal working range
1 Value too low Data valid, but below the normal working range
2 Faulty 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 a mechanical system
8 Mechanical or electrical fault Abnormal frequency
9 Communication error Abnormal update rate
10 Mechanical or electrical fault Abnormally strong vibrations
11 Unknown fault Non-identifiable fault
12 Component fault Faulty unit or component
13 Out of calibration Calibration values outside limits
14 Unknown fault Special instructions
15 Unknown fault Reserved for future use

9
Group 28 MID 249 BBM Malfunction

Measurements
Measurements towards the control unit are performed
with 9813194, 9998533 and adapter 9998699, which is
connected to the control unit’s connector. This allows
direct voltage and resistance measurements on the
control unit pins.

Voltage measurement at the control unit

To measure the signal between a control unit and a
component:

• Connect the breakout box between the control unit and

the cabling.

• Put the start switch in the drive position (II).

Resistance measurement of component

To measure the resistance of a component and the
current path:

• Connect the breakout box only to the cabling.

• Put the start switch in the stop position (0).

Resistance measurement at a component

To measure a component’s resistance:

• Connect the breakout box only to the component.

• Put the start switch in the stop position (0).

Voltage measurement at component

To measure the signal between a control unit and a
component:

• Connect the breakout box between the control unit and

the component.

• Put the start switch in the drive position (II).

Resistance measurement of cabling

To measure the resistance in cabling:

• Connect a breakout box to each end of the cable.

• Put the start switch in the stop position (0).

10
Group 28 MID 249 BBM Malfunction

Explanation of fault code table

For each fault code, there are three tables and one
illustration that give general information on the fault code
and describe suitable measurements that should be taken
to localise the source of the fault.

First table, general information

Engine type: Specifies engine type to which the current fault code is implemented.
Component number: Number of the component whose subsystem is causing the fault code.
Wiring diagram: Designation of relevant wiring diagrams in the service handbook for
the electrical system of the bus model in question and (in brackets) the
designation of the wiring diagram in service literature for previous electrical
architectures.
General Symptoms which occur for all types of faults (FMI) with that fault code.
fault symptoms:
Appropriate test Test in VCADS Pro suitable for further investigation of the component.
in VCADS Pro:
Status test Specifies whether there is a relevant status test for the component which can
in BIC: be carried out directly in the instrument control unit display.
Adapter on Instructions on which adapter to use on the component connector while
component: taking measurements.
Adapter on Instructions on which type of adapter to use on the control unit connector
control unit: while taking measurements.
Illustration: Schematic illustration of the component subsystem. The relevant pins on
the control unit and measurement points on the component are shown
in the illustration.

Second table, information on fault types

Type of fault: Specifies the fault types (FMI) that can occur for that fault code.
Symptom: Describes which fault symptoms occur for the various fault types.
Possible cause: Indicates the faults which can be the cause of the fault code for a fault type.

Third table, measurements

Measurement: Indicates the part the measurement is intended to check.
Measurement method: The illustrations specify whether:

• the control unit connector should be connected or disconnected

• the component connector should be connected or disconnected

• the adapter should be connected to the component or to the control unit.

Key position: Shows whether the starter switch/power supply switch should be in the stop
position (0) or drive position (II).
Measurement points: Describes which pins on the control unit (socket in the breakout box) or
measurement points on the component on which the measurement should be
carried out.
Expected value: Indicates with 20 % accuracy the values the measurement should give if
the part (component) is functioning normally. Also shows whether voltage
or resistance should be measured.
Miscellaneous: Special conditions or prerequisites for correct measurements.

11
Group 28 MID 249 BBM Malfunction

MID 249 SID 226 Short circuit, neutral gear

Component number: A90

Wiring diagram: AD
General fault symptom: Yellow information
lamp
Adapter on control unit: 999533, 9813194
Adapter on component: 9998534

T9008287

Type of Symptom: Possible cause:

fault:
FMI 4
• Yellow warning lamp • Abnormally low voltage or short circuit to lower
voltage

Measurements
Measurements Measurement method Key Meas- Ex- Meas- Other
position urement pected ured
points value value
Signal, neutral gear II A25 — U≈0V Active
A12
U ≈ Ubat Inactive

12
Group 28 MID 249 BBM Malfunction

MID 249 SID 231 J1939 Control link BBM

Component number: A90

Wiring diagram: AD
General fault symptom: Yellow information
lamp on
Adapter on control unit: 9998533, 9813194
T9008283

Type of Symptom: Possible cause:

fault:
FMI 2
• Reduced functionality • Break in wire between the BBM and the other
control units
• Short circuit to ground
• Short to voltage
• Faulty BBM control unit

Measurements
Measurements Measurement method Key Meas- Ex- Meas- Other
position urement pected ured
points value value
Control link SAE II C4 — U = 2.5 —
J1939, High Ground 4V

Control link SAE II C5 — U=1—

J1939 Low Ground 2.5 V

Control link SAE 0 C4 — C5 R ≈ 60 Two ter-

J1939, High/low mination
resistors
R ≈ 120 One ter-
mination
resistor

13
Group 28 MID 249 BBM Malfunction

MID 249 SID 250 SAE J1708 Information link

Component number: A90

Wiring diagram: AD
General fault symptom: Yellow warning lamp
Fault code
Adapter on control unit: 9998533, 9813194
T3017382

Type of Symptom: Possible cause:

fault:
FMI 2
• Yellow information lamp • Internal fault in control unit
• There is no information from the BBM on the
information link

Measurements
Measurements Measurement method Key Meas- Ex- Meas- Other
position urement pected ured
points value value
Information link SAE II C1 — U=0—
J1587/1708, high Ground 5V

Information link SAE II C2 — U=0—

J1587/1708, low Ground 5V

14
Group 28 MID 249 BBM Malfunction

MID 249 SID 253 Calibration memory EEPROM

Component number: A90

Wiring diagram: AD
General fault symptom: Yellow warning lamp
Fault code
Adapter on control unit: 9998533, 9813194

Type of Symptom: Possible cause:

fault:
FMI 2
• Yellow information lamp • Incorrectly programmed control unit

15
Group 28 MID 249 BBM Malfunction

MID 249 PSID 101 Starter inhibitor

Component number: A90

Wiring diagram: AD
General fault symptom: Yellow information
lamp
Adapter on control unit: 9998533, 9813194

T9008284

Type of Symptom: Possible cause:

fault:
FMI 3
• Yellow warning lamp • Abnormally high voltage or short circuit to higher
voltage
FMI 7
• Mechanical fault • Incorrect response from a mechanical system

Measurements
Measurements Measurement method Key Meas- Ex- Meas- Other
position urement pected ured
points value value
Start inhibit, start II B16 — U≈0V
relay A12
U ≈ Ubat
A26 — U≈0V
A12
U ≈ Ubat

16
Group 28 MID 249 BBM Malfunction

MID 249 PSID 102 Emergency switch

Component number: A90

Wiring diagram: AD
General fault symptom: Yellow information
lamp
Adapter on control unit: 9998533, 9813194

T9008285

Type of Symptom: Possible cause:

fault:
FMI 3
• Yellow warning lamp • Abnormally high voltage or short circuit to higher
voltage

Measurements
Measurements Measurement method Key Meas- Ex- Meas- Other
position urement pected ured
points value value
Emergency switch, II A14 — U≈0V Inactive
signal A12
U ≈ Ubat Active

Emergency switch, II A4 — U≈0V Inactive

signal A12
U ≈ Ubat Active

17
Group 28 MID 249 BBM Malfunction

MID 249 PSID 105 Sensor, Engine Hatch

Component number: A90

Wiring diagram: AD
General fault symptom: Yellow information
lamp
Adapter on control unit: 9998533, 9813194
T9008286

Type of Symptom: Possible cause:

fault:
FMI 5
• Yellow warning lamp • Abnormally low current or short circuit to ground
• Electrical fault

Measurements
Measurements Measurement method Key Meas- Ex- Meas- Other
position urement pected ured
points value value
Start inhibit, start II B29 — U≈0V
relay A12
U ≈ Ubat

18
Group 28 MID 249 BBM Malfunction

MID 249 PSID 106 D-bus

Component number: A90

Wiring diagram: AD
General fault symptom: Yellow information
lamp
Adapter on control unit: 9998533, 9813194

Type of Symptom: Possible cause:

fault:
FMI 2
• Yellow warning lamp • Intermittent or incorrect data from control unit
• Faulty data

19
 Volvo Bus Corporation
Göteborg, Sweden

20 013143 English . Printed in Sweden