Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
Date Group No. Page
This Service Bulletin replaces SB 263–25, “E-Viscous
Fan, Fault Tracing, Checklist T” (11.2004), publication no.
4.2005 263 25 1(19)
PV776–20 015668.
E-Viscous Fan
Fault tracing, Checklist T
D12D
VN, VHD VERSION2

E-Viscous Fan, Fault Tracing, Checklist T

W2004374

This information covers the troubleshooting of the E-Viscous fan on the VN/VHD
VERSION2 equipped with the Volvo D12D engine.

For more information on the design and function of the E-Viscous fan, refer to Service
Information1.

Contents
“E-Viscous Fan, Overview” page 3

“Fan, Fault Tracing” page 5

1
IMPACT or ID DVD, Info type “Description” Group 2631

PV776-20 024282 USA16711

Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 2(19)

Fault Tracing, General Guide

You must read and understand the precautions and guidelines in Service Information,
group 20, "General Safety Practices, Engine" before performing any procedure. If
you are not properly trained and certified in a procedure, ask your supervisor for
training before you perform it.

To use this checklist:

1 • Complete basic data gathering

• Read fault codes
• Check vehicle parameters

2 Use the recommendations in appropriate symptom information, plus the

information gathered above to provide a foundation for continued fault tracing
using this checklist.

One fault often affects other systems. Therefore, it is important to confirm or

eliminate suspected causes of faults at an early stage, using tests in VCADS
Pro.
For more information on the design and function of the
E-Viscous fan, refer to Service Information2.

2
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Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 3(19)

E-Viscous Fan, Overview

W2004519

• A14 - Engine ECU

• A17 - Vehicle ECU
• A34 - Climate Control ECU
• A43 - E-Viscous fan
• B21 - Engine coolant temperature sensor
• B32 - Fan speed sensor
• E32A - HVAC Unit
• F80 - Fan solenoid power supply fuse
• Y35 - Fan solenoid
• Y42 - A/C compressor magnetic clutch
Volvo Trucks North America, Inc.
Service Bulletin
E-Viscous Fan, General
The Electronically controlled viscous fan (E-Viscous)
(A43) is a low maintenance system that reduces
noise (due to low engagement rates) and lowers fuel
consumption. Its features are:
• Low idle speed.
• Fan speed regulated according to cooling system
requirements.
• More stable coolant temperatures (less fluctuations).
• Increased performance life (slip heat protection).
• Increased torque capacity (compared to ON/OFF fans).
• Soft engagements (no torque-peaks at engagement).
The E-viscous fan is of a viscous type; the fan rotation
speed is controlled by a solenoid valve (Y35) instead
of air sensing thermal control (bimetal sensor), which
is used on mechanical viscous fans. The fan speed is
electronically controlled by the Engine ECU (A14) and has
a variable speed control. E-viscous fans are equipped
with a fan speed sensor (B32) connected to the engine
ECU. The engine ECU determines how much fan speed
is required, based on the inputs listed below.
E-viscous fans have a low idling speed (200-300 rpm)
compared to that of the mechanical viscous fans (600-900
rpm). Electronically controlled fans have a fail safe
concept (or mechanism). If there is an electrical fault
in the fan, connections, or wiring the fan will run fully
engaged at the highest possible speed. The purpose of
this function is to avoid engine overheating though an
electrical fault has occurred. If an electrical fault occurs
the driver is warned by the yellow “CHECK” warning lamp
in the instrument cluster.
The fan drive remains engaged until a signal is received
from the engine ECU to disengage fan.
Fan speed is requested by a number of different inputs.
The following inputs (parameters) can send request for
fan speed to the engine ECU.
• Coolant temperature. (B21)
• Engine ECU temperature. (A14)
• Climate control system. (A34)
Note: Among the systems that request fan activation,
the system that requests the highest speed will have
its request implemented. The engine ECU always
determines which system is prioritized and which fan
speed is set.
3
IMPACT or ID DVD, Info type “Specifications” Group 26, Binder set: Specifications, Group 20.
4
IMPACT or ID DVD, Info type “Specifications” Group 26, Binder set: Specifications, Group 20.
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Date Group No. Page
4.2005 263 25 4(19)
Coolant Temperature
Coolant temperature is the most important input
(parameter) that determines the fan speed. This
maintains an even and normal coolant temperature. The
coolant temperature sensor (B21) signal is read by the
Engine ECU (A14). For fan activation and deactivation
temperatures, Refer to service information "Cooling
Systems"3
Engine ECU Temperature
In extreme conditions, the engine ECU can request
activation of the fan if the engine ECU temperature
exceeds a specified temperature.4
Climate Control System
The Climate Control system (A34) requests fan activation
in certain conditions based on inputs like vehicle speed,
ambient temperature and engine speed. The A/C
compressor magnetic clutch (Y42) must be activated
for the "On Demand" fan speeds (programmed fan
speeds). The Engine ECU is programmed to activate the
E-viscous fan at certain speeds depending on the inputs
(parameters) listed above. This function is designed to
keep the pressure in the A/C system down and maintain
good performance.
When the A/C system refrigerant pressure exceeds a
specified pressure the system can request fan activation
regardless of vehicle speed, ambient temperature and
engine speed (Max fan speeds). The A/C pressure sensor
(a sub-component of E32A) signal is read by the Climate
Control ECU (A34). The Climate Control is hard-wired to
the vehicle ECU (A17). Under normal conditions (no fan
request) the Climate Control grounds the signal from the
VECU. The Climate Control breaks the ground, initiating
a fan request when the refrigerant pressure is high. The
VECU sends request via the data link to the engine ECU
to cool the condenser.
For more information on the A/C system refer to Service
information Cab Climate Unit, Specification, Design and
Function5.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 5(19)

Fan, Fault Tracing

Also see:
“Fault Tracing, General Guide” page 2 and“E-Viscous Fan, Overview” page 3

Symptom Applicable checklist steps

Active fault codes MID 128 PID26 and/or SID33 2
Active fault code MID 128 PID 26, FMI 8 2, 3, 4, 5, 6
Fan constantly engaged 1, 2, 3, 6, 7, 8, 9
Fan does not fully engage 2, 3, 4, 5, 6, 7, 8, 9
Excessive noise from fan 3, 4, 5, 6
High coolant temperature 3, 4, 6, 8 ,9

Vehicle Chassis Number Mileage Customer

Yes No

1 “Engine ECU (Software Check)” page 7

Is the Engine ECU programmed for the E-viscous fan?

Action:

2 “Fault Code Read Out” page 7

Are there active fault codes present that affect fan control?

Action:

3 “Engine Cooling Fan, Test (VCADS Pro)” page 8

Are the checked electric controls for fan activation working correctly?

Do the requested fan activation conditions correspond with the actual conditions?

Action:

4 “Fan Drive Belt, Check” page 13

Is the fan belt in good condition and not damaged?

Does the fan belt tensioner function properly and provide correct fan belt tension?

Action:

5 “Fan Clearance Between Fan Blade and Fan Shroud” page 13

Does the fan have proper clearance between fan blade and fan shroud ?

Action:

6 “Fan Drive/Clutch, Check (Mechanical)” page 13

Are there any physical signs of damage, leakage or bearing faults to the fan assembly?

Action:

7 “Engine ECU, Check” page 14

Does the ECU send correct signals to the fan solenoid?

Action:

8 “Fan Speed Check, Manual” page 17

Does the fan fully disengage when the solenoid is activated by external power source?

Does the fan fully engage when the solenoid is not activated by external power source?

Action:

9 “Electrical Circuit, Fault Tracing” page 19

Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 6(19)

Vehicle Chassis Number Mileage Customer

Yes No

Is the electrical circuit correct?

Action:

Notes:

Completed by: Dealer: Date:

Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 7(19)

Engine ECU (Software Check)

Special tools: VCADS Pro, 9998555,
9990137
1
Connect PC (VCADS Pro) to diagnostics connector.

2
Select the Vehicle Information Test in function group 1,
Engine MID 128.

3
Verify that the engine software is programmed for the
E-viscous fan in Data set 2:
Sub dataset: "software number" Fan, VISE

Note: If there is no "Fan VISE" sub dataset listed in the

engine ECU Dataset 2 information, or if there is one listed
as "Fan ON/OFF", the engine software does not support
the E-viscous fan. In this case, contact Technical Support
at Volvo Trucks North America for assistance.

Note: It is possible that some D12D truck engines built

prior to May 2003 may not have the caption “Fan, VISE”,
however Sub-data set number “20545181” should be
listed in these models. Trucks built after May 2003 should
have this caption listed in the Sub-data set number.

Fault Code Read Out

If there are active fault codes, see MID 128 Fault Code6
or MID 146 Fault codes7.
Fan constantly engaged:

• MID 128, PID 26, FMI 3/8

• MID 128, SID 33, FMI 3/5

• MID 128, PID 110, FMI 0/4/5

• MID 128, PPID 119 FMI 0

• MID 146, SID 15 FMI 3

Note: MID 128, SID 33, FMI 5 in combination with MID

128, PPID 122, PPID 124 and SID 78 indicates the
fuse (F80) may be blown.
Fan does not engage:

• MID 128, SID 33, FMI 4

6
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Service Bulletin 4.2005 263 25 8(19)

Engine Cooling Fan, Test (VCADS Pro)

Engine Cooling Fan Test is used to check the fan control
functions. It can possibly check activation status, fan
activation level and determine the function or system that
requests fan activation. It can also activate and deactivate
the fan to check the functionality in the fan clutch.

Note: When diagnosing a faulty fan drive/clutch,

be aware that when differential speed between
the primary disk, housing (engine at idle) and
working chamber is completely filled with oil, the fan
disengagement may take several minutes.

1
Connect VCADS Pro and run the test. Follow the
instructions in VCADS pro.

Fan activation request from engine:

Coolant temperature Fan Speed

Start temperature is 90 C 600 rpm fan speed

(194 F) requested

> 93 C (199 F) Variable fan speed

requested

Engine ECU Temperature Fan Speed

>100 C (212 F) 1200 rpm fan speed

requested

< 95 C (203 F) Deactivated

If the coolant symbol remains green or the coolant

temperature is above normal, refer to Service information,
High Coolant Temperature Fault Tracing providing there is
no fault with fan.8.
EECU Temperature: This symbol should be green only in
extreme conditions. To check the accuracy of the sensor,
compare EECU temperature to ambient temperature
when the engine is cold.

2
Fan Activation Request from the VECU/Climate
Control

Climate control system requests fan activation when

the refrigerant pressure in the climate control system
is too high.

Note: If the "Air conditioning via VECU, status" symbol

is green and A/C is OFF when test ran, or if Climate
control system is suspected to request fan activation
incorrectly, refer to step 4.

8
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Service Bulletin 4.2005 263 25 9(19)

3
Fan request from VCADS Pro:

Also see evaluation and instructions in VCADS Pro.

Symptom:

Fan constantly engaged: Deactivate fan with VCADS

Pro. Ensure deactivation status is approved. Ensure the
fan deactivates.

If fan deactivates, there is no fault in the fan clutch or

ECU. Check "Request Fan Activation" in VCADS Pro.
Note: The fan speed percentage "Sensor for fan speed"
should read approx. 20% when fan is fully disengaged
(depending on temperature and engine speed).

If fan does not deactivate, see:

• “Fan Drive/Clutch, Check (Mechanical)” page 13

• “Engine ECU, Check” page 14

• “Fan Speed Check, Manual” page 17

• “Climate control system/VECU check”, step 4.

Fan does not fully engage: Activate the fan and with
VCADS Pro. Check that the activation status is approved.
Check that the fan activates.

If fan activates there is no fault in the fan clutch or ECU.

Note: The fan speed percentage "Sensor for fan speed"

should read approx. 80 - 95% when fan is fully engaged.
If fan does not activate, see:

• “Fan Drive Belt, Check” page 13

• “Fan Drive/Clutch, Check (Mechanical)” page 13

• “Engine ECU, Check” page 14

• “Fan Speed Check, Manual” page 17

4
Climate Control System/VECU Check:
The A/C system can be disabled to isolate it from the
other systems. VECU ignores request from A/C when
parameter CX is set to “No”. Parameter "CX "Air
conditioning installed" normally requires connection to
Central systems to change this parameter. If Modem
line or Network connection is not connected to PC,
VCADS can be put into Intermediate storage function to
temporarily change this parameter for this check. Go the
tool bar in top of screen and select:

• Tools
• Options
• General
Click on the Intermediate storage box, once the check is in
place click "OK". A small PC is shown in the lower part of
the screen indicating that Intermediate Storage is active.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 10(19)

5
Open Parameter programming in Group 1 of VCADS.
Start test, select parameter CX "Air conditioning installed’
under Group view Vehicle or MID view 144.

6
If parameter CX is programmed to "Yes", temporarily
change to "NO" for this test, follow prompt and exit test.

7
With the engine running, open engine cooling fan test and
start test, take note of the fan speed after engine runs
for several minutes. This determines if fan deactivates
once CX is set to "NO".

8
If the engine fan was continuously running before this
parameter was changed and the fan deactivates after
the A/C was turned off (parameter CX) this indicates
either Climate Control System or VECU is requesting fan
activation.

9
Open Parameter programming in Group 1. Change
parameter CX back to "Yes", follow prompt and exit test.
See next step for VECU input checks.

VECU Input Check:

10
Remove fuse/relay center cover in the dash, remove
fuse/relay mounting bolts and lift away from the dash to
enable access to VECU input check.

11
Connect breakout harness 9813194 and measurement
box 9998699 between PA – connector on VECU and
harness.

Note: Use overlay 85104407 with measurement box

9998699
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 11(19)

12
Turn the ignition key switch to the “ON” position. Obtain
the following measurements:

• Air conditioning PA24 (signal) – PA12 (ground) =

approx. 0 volts (no fan request from A/C)
Approx. 12 volts (fan request by A/C)

Note: If fault code MID 146 FMI 3 is active it is likely

the signal wire between Climate control and VECU
is short-circuited to B+.
If fault code MID 146 FMI 3 is not active it is likely the A/C
pressure switch is faulty or there is an open circuit on the
signal wire between the Climate Control and VECU.
Manual fan switch input (this switch is not available on
production vehicles) PA19 (signal) – PA12 (ground) =
approx. 0 volts (no fan request).
W2004524 approx. 12 volts (manual switch “ON” if it has been added
or PA19 short circuited to B+)

13
A/C Pressure Switch Check:
Connect breakout harness 9998534 between A/C
pressure sensor and harness. Connect multimeter
J-39200 to pin 2 (red lead) and pin 4 (black lead).

14
Turn the ignition key switch to the “ON” position, if voltage
is above approx. 3.1 and up to 4.5 volts the climate
control interprets this as high refrigerant pressure (engine
fan requested). Normally with the A/C compressor "OFF"
the voltage signal is approx. 1 volt.

W2004526
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 12(19)

15
If the A/C pressure switch voltage is normal, check the
signal wire between Climate control and VECU for
open circuit. BSB2 (Climate control) - PA24 (VECU) =
< 5 ohms.
Tools and measurement points:

• Climate control, breakout harness 9990025 and

measurement box 9998699 (with overlay 85104410)
connected to brown 21 pin connector only. (socket 2 in
the 21 pin brown grid)
• VECU, breakout harness 9813194 and measurement
box 9998699 (with overlay 85104407) connected to
green 30 pin connector only. (socket 24 in the 30
pin green grid)
For more information on the Climate control system, refer
to Service information, Climate System Troubleshooting9.

9
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Service Bulletin 4.2005 263 25 13(19)

Fan Drive Belt, Check

1
Check fan belt condition and tension. If the fan belt is in
bad condition or the belt tensioner is not working properly
there will be an excessive noise from the fan belt when
the fan activates. If no fault found continue fault tracing
with next step in checklist.

Fan Clearance Between Fan Blade and Fan Shroud

Possible fault code: MID 128 PID 26 FMI 8 Fan speed
percent.

1
Ensure the fan blades have enough clearance with the
fan shroud. If not, the fan speed signal to the ECU may
be irregular and fault code set.

2
Inspect the fan blade for damage or cracks, if any damage
is found with the fan, the fan assembly must be replaced.
If no fault found continue fault tracing with next step
in checklist.

Fan Drive/Clutch, Check (Mechanical)

DANGER
Ensure the Engine is “NOT running” and the
Ignition key is “OFF” before these checks are
performed. Cooling fan may engage without warning.
Hands and/or fingers in the path of the fan blades can
be injured or severed. To avoid injury, keep hands and
fingers away from the fan while the engine is running.

Fan Does Not Fully Engage:

1
Check the fan drive for evidence of oil leaks around the
outer circumference of the housing.

2
Rotate the fan by hand with the fan belt installed. This
requires moderate force due to the fluid inside the drive
clutch. If the fan is rotated with little force when the clutch
is cold this indicates possible loss of fluid or a faulty clutch.

3
Pull the fan back and forth to check for bearing wear, if
any end play is felt this indicates bearing wear.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 14(19)

Fan Constantly Engaged

4
Turn the fan by hand, the fan should turn easily when the
fan clutch is at operating temperature and slightly harder
when the clutch is cold. Rotate the fan by hand with the
fan belt installed. This requires moderate force due to the
fluid inside of the drive clutch (clutch cold) . Check for
evidence of internal noise, roughness or binding as the
fan is being rotated. The fan should rotate with little force
when the clutch is at operating temperature.

5
If there is any uneven feeling when the fan is rotated,
this may result in the fan clutch sticking and running
continuously. Replace the fan assembly if there are any
abnormalities in the fan drive. If no fault found continue
fault tracing with next step in checklist.

Engine ECU, Check

The EECU and other electrical component faults involved
in the electrical fan circuit should be covered by the
EECU’s diagnostic system and set fault code. To verify
that the signal to the fan solenoid from the EECU is
correct, perform following procedure.

Possible fault code: MID 128 SID 33 Fan control.

Note: Perform the following checks with coolant

temperature below 70 C (158 F) and Air conditioning
system “OFF”.

1
Disconnect the EB connector (top connector) from the
EECU. Check for damage on pin (EB49) on the EECU
and if the terminal is pushed back out of the socket
in the connector.

W2004493
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 15(19)

2
Connect adapter 9990014 and measurement box
9998699 between EECU and EB connector. Use
multimeter J-39200 and connect red test lead to pin
EB49 (control wire, ground) and black lead to EB59
(EECU main ground).

Note: Before check is made, fault code MID 128 SID 33

should not be active. (no electrical faults on fan circuit).

W2004490

DANGER
Cooling fan may engage without warning. Hands
and/or fingers in the path of the fan blades can be
injured or severed. To avoid injury, keep hands and
fingers away from the fan while the engine is running.

Connect VCADS Pro and open Engine Cooling Fan, Test

2631-08-03-01.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 16(19)

4
With the engine running, start the Engine Cooling Fan
test. Take note of the "Fan Status" symbol.
If symbol is gray:

• No fan activation requested (EECU output EB49:

ground signal). Voltage reading should be approx. 0
volts.
If symbol is green:

• Fan activation requested (EECU output EB49: no

ground signal or PWM signal). Voltage reading
approx. 12 Volts max fan speed (1-12 Volts, variable
fan speed).

Note: The EECU controls the fan speed by sending out a

PWM (Pulse Width Modulated) signal (pin EB49) to the
fan clutch solenoid, i.e. the voltage to the solenoid varies
depending on the fan speed request.

Symbol is gray, use "Activation fan clutch" in VCADS

Pro test and measure voltage.

• Symbol turns green, activation by VCADS Pro

succeeded. No fault on EECU exciter (driver). Voltage
reading should be approx. 12 Volts.
• Symbol remains gray, activation by VCADS Pro fails.
• Symbol indicates fault by exclamation mark (!).
Symbol is green, use "Deactivating fan clutch" in
VCADS Pro test and measure voltage.

• Symbol turns gray, deactivation by VCADS Pro

succeeded. No fault on EECU exciter (driver). Voltage
reading should be approx. 0 Volts.
• Symbol remains green, deactivation by VCADS
Pro fails.
• If symbol indicates fault by exclamation mark (!).

If no faults found continue fault tracing with next step

in checklist.

If test fails check EECU, refer to Engine ECU fault

tracing10.
If exclamation mark (!), refer to MID 128 Fault Codes11.

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Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 17(19)

Fan Speed Check, Manual

DANGER
These checks are performed with Engine “running”
Cooling fan may engage without warning. Hands
and/or fingers in the path of the fan blades can be
injured or severed. To avoid injury, keep hands and
fingers away from the fan while the engine is running.

Note: Fault code MID 128 SID 33 FMI 4 is set during this
check, erase the fault code after test is performed.

Symptom, Fan Constantly Engaged

1
Connect breakout box 9998567 between the engine
harness connector and the fan harness connector, secure
harness and breakout box away from fan with tie straps.

2
Insert test wire to socket 3 of the breakout box and
connect the other end to ground cable on the alternator.

W2004522

3
Use a suitable photo tachometer to check fan speed,
apply reflective tape in an easily accessible location
on the fan blade.

4
Before actual test is performed, verify that 12 volts is
present at fan connector to ensure the power is supplied
to solenoid. Ignition key in the “ON” position and engine
not running, socket 4 - ground is approx. 12 volts.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2005 263 25 18(19)

5
Crank engine and run engine at high idle speed and
check that fan disengagement occurs.
First perform check with the engine speed at 1500 rpm’s
or higher, fan speed should be approx. 200 - 350 rpms.
Perform check with the engine idle speed. Fan speed
should be approximately 200 - 350 rpms.
Note: Fan disengagement could take up to 5 minutes
or more, depending on torque fluid temperature in fan
drive/clutch and engine speed.

W2004523

6
If fan does not disengage when power and ground are
applied to fan solenoid the following components may be
faulty. If the fan speed is not within the specified rpm’s
or does not disengage when fan solenoid is physically
grounded, the components listed below may be faulty.

• Terminals connections.

• Wiring harness between 7-pin connector and solenoid.

• Fan solenoid.

• Electro-mechanical malfunction (solenoid/valve lever).

Replace the fan assembly, Refer to service information,
E-Viscous Fan Replacement12.

If the fan disengages properly when power and ground

are applied to the fan solenoid this indicates that the fan
assembly is functioning properly.

Symptom — Fan Does Not Fully

Engage:
1
Disconnect the 7-pin connector to the fan assembly and
secure harness away from fan.

2
Use a suitable photo tachometer to check fan speed,
apply reflective tape in an easily accessible location
on the fan blade.

3
Crank engine and run engine at high idle speed for
several minutes and check fan speed. With the connector
disconnected the solenoid valve is closed and full fan
engagement should occur.

12
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Service Bulletin 4.2005 263 25 19(19)

4
The fan speed when measured with photo tach should be
as described: Example:
Fan speed: approx. 115% - 125% of engine speed.
Engine speed 1500 rpm,s x 120% = 1800 rpm’s fan
speed.
Set engine speed to approx. 1500 rpm’s and measure
fan speed.
Fan speed should be approx. 1725 - 2000 rpm’s.

W2004523

5
If the fan does not fully engage when the 7-pin connector
is disconnected the fan assembly must be replaced. Refer
to service information, E- Viscous Fan Replacement13.

Electrical Circuit, Fault Tracing

If no faults are found by following all previous steps in
this checklist, check the electrical circuits. MID 128
Fault Codes14.
Symptom — Fan constantly engaged, see fault
tracing in order as follows for:

• SID 33, FMI 3 and 5

• PID 26, FMI 3 and 8

Symptom — Fan does not engage, see fault tracing
for:

• SID 33, FMI 4

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