Service Manual

Buses
Group 93
Release 02
MID 249 BBM
Multiplex electrical system Version 2

20 035638
 Foreword
Descriptions and instructions in this handbook are based on design and
method studies up to and including June 2005.

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 035638

© 2005 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.
ENG17760
 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 Bodybuilder module, fault codes ........................................... 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 SID 254 Control unit .............................................................. 16
MID 249 PSID 101 Starter inhibitor ..................................................... 17
MID 249 PSID 102 Emergency switch ................................................. 18
MID 249 PSID 105 Sensor, Engine Hatch ........................................... 19
MID 249 PSID 106 D-bus .................................................................... 20

1
Group 93 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 93 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 93 MID 249 BBM Tools

Tools
Special tools, BBM

T0013381

9998699 9998533 9998604

Adapter for A. Blue connector to
Breakout box, 62-pin orange connector block Adaptor for fault tracing.

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

4
Group 93 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 93 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 km/h
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 93 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

A11 Oil separator B11 Switch, parking brake

A12 Ground connection B12 Switch, jack-knife warning critical

angle articulated bus
A13 Power supply, (+30)
B13 Switch, jack-knife alarm critical angle
A14 Battery main switch articulated bus
A15 D-bus, high B15 Relay, power supply (+30)
A16 D-bus, low B16 Relay, start inhibit
A17 Service order, BB4:2 B17 Connected to A23
A18 Toilet, level warning, BB4:3 B21 Braking request, sensor turn table
A19 Toilet, engaged, BB4:4 B22 Sensor, ground brake pressure third
braking circuit
A20 Door fault, BB4:5
B29 Switch, engine hatch
A21 Fire alarm, body, BB1:3
B30 Switch, luggage compartment hatch
A23 Sensor, fire alarm engine
compartment
Connector block C
A24 Engine torque 2.75%
Pin no. Function
A25 Neutral gear
C1 Data link J1708B
A26 Start inhibit
C2 Data link J1708A
A27 Hydraulic pressure
C4 J1939 control link CANH
A28 Engine torque 1.50%
C5 J1939 control link CANL
A29 Start button, rear of engine
compartment
A30 Jack-knife control switch

7
Group 93 MID 249 BBM Malfunction

Malfunction
MID 249 Bodybuilder module, fault codes
• “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
“MID 249 SID 254 Control unit” page 16

PSID
“MID 249 PSID 101 Starter inhibitor” page 17
“MID 249 PSID 102 Emergency switch” page 18
“MID 249 PSID 105 Sensor, Engine Hatch” page 19
“MID 249 PSID 106 D-bus” page 20

8
Group 93 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 93 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 93 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

There are two types of measurements, resistance and voltage, which are divided into separate tables. Above and to
the left of each table there is an illustration showing how to connect the measurement equipment to the component
for that particular reading.
Measurement: Indicates the part the measurement is intended to check.
Key position: Shows the switch position applicable to the particular reading.
Measurement points: There are two columns under measurement points, breakout box and wiring
diagram. The“breakout box” column shows the numbers representing the
markings on breakout box 999 86 99. The wiring diagram shows the names
of the pins on a component or ECU in a Volvo wiring diagram. The first table
shows which wiring diagram applies.
Expected value: Indicates with 20 % accuracy the values the measurement should give if the
part (component) the measurements are for is complete.
Measured value: The column is for entering the measured values.
Miscellaneous: Any special circumstances or conditions concerning the particular reading
are entered here.

11
Group 93 MID 249 BBM Malfunction

MID 249 SID 226 Short circuit, neutral gear

Component number: A90

Wiring diagram: BB
General fault symptom: Yellow information
lamp
Adapter on control unit: 9998533
Other: 9998699. 9812519

Type of Symptom: Possible cause:

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

Voltage measurement

Measure- Key position Measurement points Expected Measured Other

ments value value
Breakout box Wiring
diagram
Signal, neutral II 25 – 12 A25 – A12 U = 0.5 V Neutral
gear position
U = Ubat Gear position

12
Group 93 MID 249 BBM Malfunction

MID 249 SID 231 J1939 Control link BBM

Component number: A90

Wiring diagram: XC
General fault symptom: Yellow information
lamp on
Adapter on control unit: 9998604
Other: 9998699. 9812519

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

Voltage measurement

Measure- Key position Measurement points Expected Measured Other

ments value value
Breakout box Wiring
diagram
1
J1939 control II 29 – chassis C4 – chassis U = 2.7 ± 0.3 V
link CANH ground ground
J1939 control II 30 – chassis C5 – chassis U = 2.3 ± 0.3 V 1
link CANL ground ground
1
see Service literature, group 37. IMPACT: Group 37, Diagnostics, Data links, fault tracing, for further fault tracing.

Resistance measurement

Measure- Key position Measurement points Expected Measured Other

ments value value
Breakout box Wiring
diagram
J1939 0 29 – 30 C4 — C5 R = 60 Two
control link termination
CANH/CANL resistors
R = 120 One
termination
resistor

13
Group 93 MID 249 BBM Malfunction

MID 249 SID 250 SAE J1708 Information link

Component number: A90

Wiring diagram: XC
General fault symptom: Yellow warning lamp
Fault code
Adapter on control unit: 9998604
Other: 9998699. 9812519

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

Voltage measurement

Measure- Key position Measurement points Expected Measured Other

ments value value
Breakout box Wiring
diagram
1
Data link II 26 – chassis C1 – chassis U = 0.3 -4.2 V
J1708B ground ground
Data link II 27 – chassis C2 – chassis U = 0.3 -4.2 V 1
1708A ground ground
1
The voltage varies within the interval.

14
Group 93 MID 249 BBM Malfunction

MID 249 SID 253 Calibration memory EEPROM

Component number: A90

Wiring diagram: BB
General fault symptom: Yellow warning lamp
Fault code

Type of Symptom: Possible cause:

fault:
FMI 2
• Yellow information lamp • Incorrectly programmed control unit
FMI 13
• Red information lamp • Calibration values outside limits
FMI 14
• Red information lamp • Unknown fault.

15
Group 93 MID 249 BBM Malfunction

MID 249 SID 254 Control unit

Component number: A90

Wiring diagram: XC
General fault symptom: Yellow warning lamp
Fault code

Type of Symptom: Possible cause:

fault:
FMI 12
• Yellow information lamp • Defective control unit

16
Group 93 MID 249 BBM Malfunction

MID 249 PSID 101 Starter inhibitor

Component number: A90

Wiring diagram: AA
General fault symptom: Yellow information
lamp
Adapter on control unit: 9998533
Other: 9998699, 9812519

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

Voltage measurement

Measure- Key position Measurement points Expected Measured Other

ments value value
Breakout box Wiring
diagram
Start inhibit, II 16 – 12 B16 – A12 U=0V Active
start relay
Note: Two
breakout
boxes.
U = Ubat Inactive

Note: Two
breakout
boxes.
26 – 12 A26 – A12 U = 0 -3 V Active
U = Ubat Inactive

17
Group 93 MID 249 BBM Malfunction

MID 249 PSID 102 Emergency switch

Component number: A90

Wiring diagram: AA
General fault symptom: Yellow information
lamp
Adapter on control unit: 9998533, 9813194
Other: 9998699, 9812519

Type of Symptom: Possible cause:

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

Voltage measurement

Measure- Key position Measurement points Expected Measured Other

ments value value
Breakout box Wiring
diagram
Main supply II 14 – 12 A14 – A12 U=0V Inactive
switch
U = Ubat Active
Emergency II 4 – 12 A4 – A12 U=0V Inactive
switch, signal
U = Ubat Active

18
Group 93 MID 249 BBM Malfunction

MID 249 PSID 105 Sensor, Engine Hatch

Component number: A90

Wiring diagram: BB
General fault symptom: Yellow information
lamp
Adapter on control unit: 9813194
Other: 9998699, 9812519

Type of Symptom: Possible cause:

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

Voltage measurement

Measure- Key position Measurement points Expected Measured Other

ments value value
Breakout box Wiring
diagram
Engine hatch II 29 – chassis B29 – chassis U=0V open
ground ground
U = Ubat blocked

19
Group 93 MID 249 BBM Malfunction

MID 249 PSID 106 D-bus

Component number: A90

Wiring diagram: BB
General fault symptom: Yellow information
lamp
Adapter on control unit: 9998533
Other: 9998699, 9812519

Voltage measurement

Measure- Key position Measurement points Expected Measured Other

ments value value
Breakout box Wiring
diagram
1
Control link II 15 – 12 A15 – chassis U = 2.7 (± 0.3)
J1939 CANH, ground V
D-bus
Data link II 16 – 12 A16 – chassis U = 2.3 (± 0.3) 1
J1939 CANL, ground V
D-bus
1
see Service literature, group 37. IMPACT: Group 37, Diagnostics, Data links, fault tracing, for further fault tracing.

Resistance measurement

Measure- Key position Measurement points Expected Measured Other

ments value value
Breakout box Wiring
diagram
Control 0 15 – 16 A15 – A16 R = 60 Two
link J1939, termination
terminal resistors
resistor
R = 120 One
termination
resistor

20
21
 Volvo Bus Corporation
Göteborg, Sweden

20 035638 English . Printed in Sweden