SP 386-004
Service Bulletin Details
Public Details for: SP 386-004
Fuel management module, replacement, incorrect calibration
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Service Program Trucks Volvo Trucks North America Greensboro, NC USA Date This SP replaces PV729-SP386–004 (USA65209), “Fuel Management Module, Replacement” dated 10.2014. 10.2014 Group No. 386 004 Release Page 02 1(37) Fuel Management Module, Replacement VN SP 386-004, Fuel Management Module, Replacement (October 2014) On certain Volvo CNG (Compressed Natural Gas) models, built between 03/19/2011 and 07/25/2014, the low fuel warning may come on too early and the fuel gauge may show full if the fuel level sensor signal becomes open. In addition the gauge may show lower tank levels at cold temperatures or higher tank levels at hotter temperatures. This is due to the fact that the software in the fuel management module (FMM) did not have the correct calibration, open circuit fault criteria and was not temperature compensated. To correct this issue follow the procedure below. Inspection You must read and understand the precautions and guidelines in Service Information, group 3, “General Safety Practices, Electrical” before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. The FMM may be located on the rail with frame mounted tank or either inside or outside of the access door with a cabinet mounted tanks. Look to see where the shut off valve is located and choose the correct repair below when replacing the FMM. 1 Secure the vehicle for service by parking it on a flat level surface, applying the parking brake, chocking the rear wheel, and placing the transmission in neutral. W7086748 USA67437 PV729-SP386-004 English Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 2 Check to see where the FMM is mounted by locating the shut off valve per the illustrations below. W3091600 Repair A: Tank mounted Repair B: Internal Repair C: External 3 Once the FMM location has been determined go to the appropriate Repair section labeled, A, B, or C. Page 2(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 Required Parts Quantity Part Number 1 85143376 Description Control Unit CNG Fuel Levels Repair A You must read and understand the precautions and guidelines in Service Information, group 3, “General Safety Practices, Electrical” before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. Tank mounted FMM 1 Disconnect all cables from the negative (ground) battery terminals to prevent personal injury from electrical shock and prevent damage to electrical components. W3086747 Page 3(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 2 Turn the CNG fuel system off, follow procedures as outlined: 2a. Turn the Manual Fuel System valve (red knob) to Closed. W3090943 1. CNG Fuel System Shut Off Valve Note: This valve isolates the fuel system from the engine. Page 4(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 2b. Open rear access door(s) on both tank(s) if applicable. 2c. Turn each tank valve OFF. W3090944 W3090945 Note: This will isolate each fuel tank separately from the CNG fuel system. Page 5(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 3 Remove the rear step tread from the tank identified as containing the FMM. Note: Left frame rail mount shown, right side similar. W3091719 1. Step tread 4 Remove the tank caps, tethers and top two housing screws. W3090947 1. CNG fuel caps 2. Housing screws Page 6(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 5 Remove the top cover from the tank including rear access door and tether. W3090949 1. Fasteners W3090950 W3090952 Page 7(37) Volvo Trucks North America Service Program Date 10.2014 6 Disconnect the FMM harnesses. W3090953 1. FMM Harness Connector 2. FMM Harness Connector 7 Remove FMM. W3090954 1. Fasteners Group No. Release 386 004 02 Page 8(37) Volvo Trucks North America Service Program Date 10.2014 8 Install new FMM W3090954 1. Fasteners 9 Connect the FMM harnesses. W3090953 1. FMM Harness Connector 2. FMM Harness Connector Group No. Release 386 004 02 Page 9(37) Volvo Trucks North America Service Program Date 10.2014 10 Install top cover. W3090952 W3090950 W3090949 1. Fasteners Group No. Release 386 004 02 Page 10(37) Volvo Trucks North America Service Program Date 10.2014 11 Install cap tethers, caps and additional top two screws. W3090947 1. CNG fuel caps 2. Housing screws 12 Install the step tread. W3091719 1. Step tread Group No. Release 386 004 02 Page 11(37) Volvo Trucks North America Service Program Date 10.2014 13 Turn fuel system ON, follow procedures as outlined: 13a. Turn tank valve(s) on. W3090944 W3090945 Group No. Release 386 004 02 Page 12(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 13b. “SLOWLY” turn the Fuel System Valve (red knob) to OPEN. W3090943 1. CNG Fuel System Shut Off Valve Note: Allow approximately 10 seconds of time to perform. CAUTION Failure to slowly open valve could cause damage to system by high pressure gas if opened too quickly. 14 Install all the previously removed cables to the negative (ground) battery terminals. W3086758 Page 13(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 15 Test the safety feature of the system. 15a. Start engine and then turn the engine off. 15b. Remove both tank caps and try to start the engine. • If the engine does not start, the safety feature is working properly. Proceed to next step. • If the engine starts, the safety feature is not working correctly and will need to be serviced. Note: See Agility for more information. 16 Install both fuel caps. 17 Remove the wheel chocks. W7086759 Page 14(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 Repair B You must read and understand the precautions and guidelines in Service Information, group 3, “General Safety Practices, Electrical” before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. Internal FMM 1 Disconnect all cables from the negative (ground) battery terminals to prevent personal injury from electrical shock and prevent damage to electrical components. W3086747 Page 15(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 2 Turn the CNG fuel system off, follow procedures as outlined: 2a. Turn the Manual Fuel System valve (red knob) to Closed. Note: This valve isolates the fuel system from the engine. W3090955 1. CNG Fuel System Shut Off Valve Page 16(37) Volvo Trucks North America Service Program Date 10.2014 2b. Open access door(s) W3090956 1. Access door Group No. Release 386 004 02 Page 17(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 2c. Turn each tank valve OFF. W3090957 1. Tank shut-off valve 2. Tank shut-off valve 3. Tank shut-off valve Note: This will isolate each fuel tank separately from the CNG fuel system. Page 18(37) Volvo Trucks North America Service Program Date 10.2014 3 Disconnect the FMM harnesses. W3090958 1. FMM harness connector 2. FMM harness connector 4 Remove the FMM. W3090959 1. Fasteners Group No. Release 386 004 02 Page 19(37) Volvo Trucks North America Service Program Date 10.2014 5 Install the FMM. W3090959 1. Fasteners 6 Connect the FMM harness. W3090958 1. FMM harness connector 2. FMM harness connector Group No. Release 386 004 02 Page 20(37) Volvo Trucks North America Service Program Date 10.2014 7 Turn fuel system ON, follow procedures as outlined: 7a. Turn tank valve(s) on. W3090957 1. Tank shut-off valve 2. Tank shut-off valve 3. Tank shut-off valve Group No. Release 386 004 02 Page 21(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 7b. “SLOWLY” turn the Fuel System Valve (red knob) to OPEN. W3090955 1. CNG Fuel System Shut Off Valve Note: Allow approximately 10 seconds of time to perform. CAUTION Failure to slowly open valve could cause damage to system by high pressure gas if opened too quickly. Page 22(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 8 Close the access doors. W3090956 1. Access Door 9 Install all the previously removed cables to the negative (ground) battery terminals. W3086758 Page 23(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 10 Test the safety feature of the system. 10a. Start engine and then turn the engine off. 10b. Remove both tank caps and try to start the engine. • If the engine does not start, the safety feature is working properly. Proceed to next step. • If the engine starts, the safety feature is not working correctly and will need to be serviced. Note: See Agility for more information. 11 Install both fuel caps. 12 Remove the wheel chocks. W7086759 Page 24(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 Repair C You must read and understand the precautions and guidelines in Service Information, group 3, “General Safety Practices, Electrical” before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. External FMM 1 Disconnect all cables from the negative (ground) battery terminals to prevent personal injury from electrical shock and prevent damage to electrical components. W3086747 Page 25(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 2 Turn the CNG fuel system off, follow procedures as outlined: 2a. Open the access door and turn the Manual Fuel System valve (red knob) to Closed. Note: This valve isolates the fuel system from the engine. W3090960 1. Access door W3090961 1. CNG Fuel System Shut Off Valve Page 26(37) Volvo Trucks North America Service Program Date 10.2014 2b. Open access door(s) W3090962 1. Upper access door 2. Lower access door Group No. Release 386 004 02 Page 27(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 2c. Turn each tank valve OFF. Note: This will isolate each fuel tank separately from the CNG fuel system. W3090963 1. Tank shut-off valve 2. Tank shut-off valve 3. Tank shut-off valve 4. Tank shut-off valve Page 28(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 3 Remove the lower panel from the FMM control box. Note: There are 3 screws total: 2 on the left side and 1 on the right side. W3090964 1. Fastener W3090965 1. Fastener Page 29(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 4 Disconnect the FMM harnesses. W3090966 1. FMM harness connector 2. FMM harness connector 5 Remove the FMM. W3090967 1. Fastener 2. Fastener Page 30(37) Volvo Trucks North America Service Program Date 10.2014 6 Install the FMM. W3090967 1. Fastener 2. Fastener 7 Connect the FMM harnesses. W3090966 1. FMM harness connector 2. FMM harness connector Group No. Release 386 004 02 Page 31(37) Volvo Trucks North America Service Program Date 10.2014 8 Install the lower cover. W3090965 1. Fastener W3090964 1. Fastener Group No. Release 386 004 02 Page 32(37) Volvo Trucks North America Service Program Date 10.2014 9 Turn fuel system ON, follow procedures as outlined: 9a. Turn tank valve(s) on. W3090963 1. Tank shut-off valve 2. Tank shut-off valve 3. Tank shut-off valve 4. Tank shut-off valve Group No. Release 386 004 02 Page 33(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 9b. “SLOWLY” turn the Fuel System Valve (red knob) to OPEN. W3090961 1. CNG Fuel System Shut Off Valve Note: Allow approximately 10 seconds of time to perform. CAUTION Failure to slowly open valve could cause damage to system by high pressure gas if opened too quickly. Page 34(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 10 Close the access doors. W3090962 1. Upper Access Door 2. Lower Access Door 11 Install all the previously removed cables to the negative (ground) battery terminals. W3086758 Page 35(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 12 Test the safety feature of the system. 12a. Start engine and then turn the engine off. 12b. Remove both tank caps and try to start the engine. • If the engine does not start, the safety feature is working properly. Proceed to next step. • If the engine starts, the safety feature is not working correctly and will need to be serviced. Note: See Agility for more information. 13 Install both fuel caps. 14 Remove the wheel chocks. W7086759 Page 36(37) Volvo Trucks North America Service Program Date 10.2014 Group No. Release 386 004 02 Reimbursement This repair is covered by an authorized Service Program. Reimbursement is obtained via the normal claim handling process. UCHPReimbursement eWarranty Reimbursement Claim Type (used only when uploading from the Dealer Bus. Sys.) B B Recall Status Vehicle inspected, repair not required 1- Inspected OK Vehicle repaired per instruction 2- Modified per instruction Labor Code Primary Labor Code Inspection 3000-06-09-01 0.3 hrs 38621-0-00 0.3 hrs Repair only (Repair A) 3866-03-09-02 0.8 hrs 38621-0-01 0.8 hrs Repair only (Repair B) 3866-03-09-02 0.3 hrs 38621-0-02 0.3 hrs Repair only (Repair C) 3866-03-09-02 0.5 hrs 38621-0-03 0.5 hrs Take to take charge and determine campaign status 1700-16-01-01 0.3 hrs 17003-0-01 0.3 hrs Causal Part 85143376 85143376 SCC Code S6603 NA Authorization Number NA SP386004 Expiration Date 01- Oct- 2015 01- Oct- 2015 Parts Disposition Note: Take Charge Time is not included in the Labor Code for this operation. Take charge may be eligible but can only be used once per repair visit. If vehicle is having other warranty repairs performed, take charge should be charged to the warranty repair, otherwise take charge can be charged to this service program. Page 37(37)