NHTSA ID Number: 10251324
Manufacturer Communication Number: KC-2349
TSB/Document Date: 2024-03-05
Summary
CBR = BEV Fault Code C102571 - Hybrid
/EV System, Cooling Heater Relays - Actuator Stuck
Preview Solution CBR-2349-1
BEV Fault Code C102571 - Hybrid/EV
System, Cooling Heater Relays Actuator Stuck
Published Date 21 February 2024
Valid For
Mack LR-E and Volvo VNR-E Model Year 2021 to Current
BEV units can set fault C102571 which can lead to No charge, No cab heat, and
possible unit derate/shutdown.
There are currently no diagnostic troubleshooting steps in PTT for the fault code.
Follow troubleshooting steps found in CBR solution CBR-2255 before
moving further.
1. Replace all of the Heater relays. Refer to 3119-03-02-11 Relays, Electric
Heater ESS, Replacement.
Part Number
Description
20709545
QTY
Phase 1 trucks - 4 Relays
Phase 2 trucks - 3 Relays
2. Run 2 processes in Tech Tool under Calibrate - 1700-08-03-33 Function
Parameters Reset.
Coolant heater relay, reset fuse mode
Coolant heater relay reset
3. Perform 1700-08-03-06 Sensor and Parameter Values, Monitoring and
monitor the cab heater temperatures.
; Live UI
Monitor temperatures with heater active. Temperatures should rise evenly and
settle at 140f to150f. If heaters do not heat up evenly and spike in temperature,
there is still an issue with the system. Checking coolant flow through the heaters
and performing a thorough bleeding of the system may be needed.
Related links and attachments
KC-2349 1700-08-03-33 IMG 1
KC-2349 1700-08-03-06 IMG 1
KC-2349 1700-08-03-06 IMG 2
KC-2349 1700-08-03-06 IMG 1
KC-2255
KC-2349 3119-03-02-11
KC-2349 1700-08-03-33 IMG 2
; Live UI
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IMPACT 4.07.174
2/19/2024
31904-2 Relays, Electric Heater ESS, Replacement
All
Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.
Colors used in illustrations are for highlighting purposes only and do not correspond to the
actual colors of the vehicle.
All threaded fasteners that do not have a tightening torque specification in the information are
tightened to a standard torque. Standard torques are available in the following specification.➠
Standard Tightening Torques
Special tools
88890334
1
Apply the parking brake.
2
Place the gear selector in neutral.
3
Remove the power key.
4
Safeguard the key.
5
Install the wheel chocks.
6
Disconnect all external power supply or charging devices.
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.
2 / 24
IMPACT 4.07.174
7
2/19/2024
Lock the access to the CCS (Combined Charging System).
Required material
PADLOCK
8
88890334
Set the chassis switch to position (1).
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.
3 / 24
IMPACT 4.07.174
2/19/2024
Switch, position
9
Position
Status
1
OFF
2
ON
Remove the safety pin from the slot (A) and install in the slot (B) .
Note
The purpose is to prevent unexpected movements of the switch.
DANGER
Risk of serious injury or death.
A cab that is not tilted to the end position constitutes a safety risk.
▶
It is forbidden to work in, under or in front of a cab that is not fully tilted.
▶
No persons are to remain in, under or in front of the cab while tilting is in progress.
▶
Always tilt the cab to the end position.
CAUTION
Risk of material damage.
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.
4 / 24
IMPACT 4.07.174
2/19/2024
Failure to secure loose material in the cab, to close all the doors and to have adequate space in front
of the vehicle before tilting the cab may result in material damage.
▶
Secure all loose material within the cab before tilting.
▶
Ensure that all the doors are closed.
▶
Make sure that there is adequate space in front of the vehicle before tilting the cab.
10
Tilt the cab forward.
11
Move aside the hose.
12
Remove the wing nuts.
13
Remove the washers.
14
Remove the cover.
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.
5 / 24
IMPACT 4.07.174
15
Release the clips.
16
Remove the covers.
17
Remove the nuts.
18
Remove the fuses.
2/19/2024
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.
6 / 24
IMPACT 4.07.174
2/19/2024
Note
Note the position.
19
Disconnect the cable from the negative terminal.
20
Install the plug.
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.
7 / 24
IMPACT 4.07.174
2/19/2024
Required material
PLUG
975827
21
Lock the negative terminal along with the fuses.
22
Disconnect the connectors.
Note
Note the positions.
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.
8 / 24
IMPACT 4.07.174
23
2/19/2024
Remove the cable ties.
Note
Note the positions.
24
Remove the nuts.
25
Remove the cables.
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.
9 / 24
IMPACT 4.07.174
26
Remove the screws.
27
Remove the relays.
2/19/2024
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.
10 / 24
IMPACT 4.07.174
28
Install the relays.
29
Install the screws.
30
Torque tighten the screws.
2/19/2024
Tightening torque
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.
11 / 24
IMPACT 4.07.174
2/19/2024
Power relay, main switch, screw
10 ±1.5 Nm
(7 ±1 lbf⋅ft)
31
Install the cables.
32
Install the nuts.
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TSB/Document ID: KC-2349
Replacement Service Bulletin Number:
MFR Communication Date: 2024-02-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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