IMPACT 4.04.

00 31/07/2020

Chassis ID Path
371/Diagnostics//Cables and connectors, fault tracing

Model Identity
FM (4) 139560722

Publish date ID/Operation

03/10/2017

Cables and connectors, fault tracing

Detailed fault tracing instructions for specific failure modes are described in Tech Tool.

This document is to describe how to fault trace wires and connectors in general.

Visuell checks
Check that the wires are correctly clamped and secured.
Tightly clamped wires can cause bad contact or open circuit.
Avoid cling lines too narrow for contacts.

Make sure the lines are not too tightly clamped.

Hard clamped wires can cause bad contact or open circuit.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Check that the cables not have rubbing damages. Look specifically at places where the harness is near frame edges
and consoles.

Reason for chafing damage can be:

Clamping missing
Loose clamping
Wrong clamping, (over length, too tight, stretched)

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Connectors check
Oxidation affects the resistance of a contact which can cause permanent or intermittent interruption in the electricity
circuit.

Note: Water intrusion with discolourations in Control unit connectors requires replacement of the control module

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Damaged or wrong installed terminals

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the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Check that the terminals are properly locked and cannot be pushed back
Check that the terminals are not bent or broken

To control the elasticity of the terminals and the terminals are locked in the connector, use the required test pins to
avoid damaging the terminals.

Ground connections may look good but can be corroded and/or loose which will give bad ground connection

Wire splices
For chassis harnesses, corrosion in splices and where the wires connect to a splice is common. Often it is also in areas
where the wire passes by a y- manifold and the WH is not taped.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Electrical measurements
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the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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To consider:

Never measure by piercing through the insulation and moisture seals in wires and connectors.

Measure wiring harness using multimeter and use appropriate measuring cable and measuring box.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Note: When test cable does not exist, use test pins.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Open Circuit
Checks:

Disconnect the actual connectors in both ends of the wiring harness.

Measure the resistance from each ends of the wiring harness.

Short Circuit
Checks:

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the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Splices in the wiring harness (XE12) affect the measurements why it is important to disconnect current connectors to
all components in the circuit. For example, it can be good to narrow the fault tracing in the engine wiring harness by
disconnecting the engine interface connector to the chassis.

Measurement 1: check for short circuit to ground.

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the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Measurement 2: check for short circuit to voltage.

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the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Measurement 3: Check for short circuit to any wire in the actual connector and wiring harness.

Cleaning of connectors and terminals

- It is only allowed to clean by using workshop air pressure.

Caution
If there is moisture in the connector towards a control unit it is not allowed to use workshop air pressure since
these connectors are not moisture-proof. If the control unit function is intact it’s better to let it dry by itself if
there is no discolourations in the connector. If using compressed air it is a risk that the moisture is pressed into
the control unit and followed by damages inside.

Note: Blowing to hard can cause connector seals to blow out. Do not use workshop air if it includes too much oil.

- Grease (pn 1161417) can be used in connectors to protect against moisture.

Note: Do not overfill with grease which can cause the connector seals to be pressed out.

No type of spray that contains silicone oil may be used in the connectors.

Target values

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the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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Target values may vary depending on the function of the electrical circuit. Some features are more sensitive to
deviations than others. Therefore, it is important to follow the instructions and expected values in the fault tracing
instructions when determining if there is an error or not.

Intermittent errors
Intermittent faults can be detected during the measurement by wiggle wires and connectors.

If possible, you may want to do a test run and repeat the conditions described the error occurred.

The multimeter can be used to detect a bad connection.

1. Set the multimeter to appropriate setting

2. Connect the tools according to the information in the chosen data link schematics
3. Once reading the values, press the MIN / MAX button
4. Wiggle the wires or perform a test drive while notifying the minimum and maximum values on the multimeter to
find a bad contact.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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