Volvo Penta 9L, 12L, 13L, 16L Industrial Engines Workshop Manual

Workshop Manual

Group 30 Electrical system

I

5(0)

9L, 12L, 13L, 16L

Industrial Engines

Content

General Information

00-0 General ................................................................................................ 2

Specifications

03-3 Specifications, Electrical ................................................................... 6

Safety and Other Instructions

05-1 Safety Instructions ........................................................................... 11

Special tools

08-2 Special Service Tools ....................................................................... 15

General, Complete Vehicle Software

30-0 General .............................................................................................. 17

30-2 Fault Tracing ..................................................................................... 50

Cables and fuses

37-0 Wiring Diagrams ............................................................................. 176

Miscellaneous

39-0 General ............................................................................................ 199

Alphabetical index .................................................................................. 201

References to Service Bulletins ............................................................ 203

2

00-0 General

General information

This Service Manual contains technical data, descriptions and maintenance and repair instructions for standard model Volvo Penta products. A list of these products may be found in the section Specifica-

tions.

The product designation and the serial number and specification is indicated on the engine decal or type plate. This information must be included in all correspondence regarding the product.

The service manual is produced primarily for the use of Volvo Penta workshops and their qualified personnel. It is assumed that any person using the Service

Manual has a fundamental knowledge of the product and is able to carry out mechanical and electrical work to trade standard.

Volvo Penta continually develops its products; we therefore reserve the right to make changes. All information in this manual is based on product data which was available up to the date on which the manual was printed. New working methods and significant changes introduced to the product after this date are communicated in the form of Service bulletins.

Spare Parts

Spare parts for the electrical and fuel systems are subject to various national safety standards. Volvo

Penta Original Spare Parts meet these standards. No damage of any kind caused by the use of spare parts not approved by Volvo Penta will be compensated by any warranty undertaking.

About this Workshop manual

Certified engines

When carrying out service and repair on emission-certified engines, it is important to be aware of the following:

Certification means that an engine type has been inspected and approved by the relevant authority.

The engine manufacturer guarantees that all engines of the same type are manufactured to correspond to the certified engine.

This places special demands on service and repair work, namely:

• Maintenance and service intervals recommended by Volvo Penta must be complied with.

• Only spare parts approved by Volvo Penta may be used.

• Service on injection pumps, pump settings and injectors must always be carried out by an authorized Volvo Penta workshop.

• The engine must not be converted or modified, except with accessories and service kits which

Volvo Penta has approved for the engine.

• No changes to the exhaust pipe and engine air inlet duct installations may be made.

• No warranty seals (where present on the product) may be broken by unauthorized persons.

The general instructions in the Operator's Manual concerning operation, service and maintenance apply.

IMPORTANT!

Neglected or poorly-performed care/service and the use of spare parts not approved by Volvo Penta, will mean that AB Volvo Penta no longer guarantees that the engine conforms to the certified model.

Volvo Penta accepts no responsibility for damage or costs arising as a result of failure to follow the above mentioned standards.

47701632 10-2010

00-0 General

Introduction

The working methods described in this manual are based on a workshop scenario where the product is mounted in a holding fixture. Maintenance work is often carried out in situ, in which case – if nothing else is indicated – using the same working methods as the workshop.

Warning symbols that occur in the service manual.

For significance, refer to Safety Information .

!

DANGER!

!

WARNING!

!

CAUTION!

IMPORTANT!, NOTICE! are by no means comprehensive since not everything can be foreseen as service work is carried out in the most varied of circumstances. We call attention to risks that may occur due to incorrect handling during work in a well-equipped workshop using working methods and tools tried and tested by us.

The service manual describes work operations carried out with the aid of Volvo Penta Special Tools, where such have been developed. Volvo Penta Special Tools are designed to ensure the safest and most rational working methods possible. It is therefore the responsibility of anyone using tools or working methods other than those we recommend to ensure that no risk of personal injury or mechanical damage is present, or that malfunction can result.

In some cases, special safety regulations and user instructions may be in force for the tools and chemicals mentioned in the Service Manual. These regulations must always be followed, and no special instructions regarding this are to be found in the Service Manual.

By taking these basic precautions and using common sense it will be possible to guard against most elements of risk. A clean workplace and a clean product will eliminate many risks of personal injury and malfunction.

Above all, when working on fuel systems, hydraulic systems, lubrication systems, turbochargers, inlet systems, bearings and seals, it is of the utmost importance that dirt and foreign objects are kept away, as malfunctions or shortened service intervals may otherwise result.

Repair instructions

Our mutual responsibility

Each product comprises a large number of interacting systems and components. A deviation from the technical specification may dramatically increase the environmental impact of an otherwise reliable system. It is therefore critical that the stated wear tolerances be adhered to, that systems which can be adjusted be correctly set up and that only Volvo Penta

Original Parts are used. The intervals in the care and maintenance schedule must be followed.

Some systems, e.g. fuel systems, often require special expertise and test equipment. A number of components are factory-sealed, for among other things environmental reasons. Warranty-sealed components may not be worked on without authorization to perform such work.

Remember that most chemical products, incorrectly used, are harmful to the environment. Volvo Penta recommends the use of biodegradable degreasers whenever components are cleaned, unless otherwise specified in the Service Manual. When working outdoors, take especial care to ensure that oils and wash residues etc. are correctly properly for destruction.

Tightening torques

Tightening torques for vital fasteners that must be applied using a torque wrench are indicated in the

Service Manual, chapter Tightening torques and in the Manual's work descriptions. All torque indications apply to clean threads, bolt heads and mating faces.

Indicated torque data apply to lightly-oiled or dry threads. If lubricants, locking fluids or sealants are required for fasteners, the correct type will be noted in the job description.

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00-0 General

Torque, angle tightening

When torque/angle tightening, the fastener is tightened to a specified torque, and tightening then continues through a pre-determined angle.

Example: For 90° angle tightening, the fastener is turned a further 1/4 turn in one sequence, after the specified tightening torque has been achieved.

Lock nuts

Removed locknuts may not be re-used; they must be replaced by new ones, as locking properties are impaired or lost with re-use.

In the case of lock nuts with plastic inserts the tightening torque indicated must be reduced if the nut has the same nut height as a standard, all-metal hexagonal nut.

Reduce the torque by 25% for bolt sizes of 8 mm or larger.

In the case of lock nuts with plastic inserts with a high nut-height (where the all-metal thread is as high as a standard hexagonal nut), the indicated torque applies.

Strength classes

Nuts and bolts are subdivided into different strength classes. The classification is shown by a marking on the bolt head. Markings of a higher number indicate stronger material. For example, a bolt marked 10-9 is stronger than one marked 8-8.

For this reason, it is important that when bolts are removed they are returned to their original locations on re-assembly. When replacing bolts check the applicable Spare parts catalogue to ensure the correct bolt is used.

Sealing compounds etc.

To ensure service work is correctly carried out it is important that the correct type of sealants and locking fluids are used on joints where such are required.

In each service manual section concerned, the sealants used in product manufacture are indicated. The same sealants, or sealants with equivalent properties, must be used for maintenance work.

Make sure that mating surfaces are dry and free from oil, grease, paint and anti-corrosion agent before applying sealant or locking fluid. Always follow the manufacturer's instructions regarding applicable temperatures, hardening times and such.

Two basic types of compound are used:

RTV preparations (Room Temperature Vulcanizing).

Used most often together with gaskets, e.g. sealing gasket joints, or are brushed on gaskets. RTV sealants are completely visible when the part has been removed. Old RTV sealant must be removed before the component is sealed again. Use denatured alcohol.

Anaerobic agents.

These agents cure (harden) in the absence of air.

These preparations are used when two solid components, e.g. two cast components, are fitted together without a gasket. Common uses are also to lock and seal plugs, stud threads, taps, oil pressure monitors etc.

Hardened anaerobic preparations are glassy and for this reason, the preparations are colored to make them visible. Hardened anaerobic preparations are highly resistant to solvents, and old compound cannot be removed. On re-assembly, it is important to carefully degrease and wipe dry components first, before applying new sealant in accordance with the instructions.

4 47701632 10-2010

Safety regulations for fluorocarbon rubber

Fluorocarbon rubber is a common material in sealing rings for shafts, and in O-rings, for example.

When fluorocarbon rubber is exposed to high temperatures (above 300°C/572°F), hydrofluoric acid can form. This is highly corrosive. Contact with the skin can result in severe chemical burns. Splashes in your eyes can result in chemical wounds. If you breathe in the fumes, your lungs can be permanently damaged.

WARNING!

Seals must never be cut with a torch, or be burnt afterwards in an uncontrolled manner. Risk for poisonous gases.

WARNING!

Always use chloroprene rubber gloves (gloves for chemicals handling) and goggles. Handle the removed seal in the same way as corrosive acid. All residue, including ash, can be highly corrosive. Never use compressed air to blow clean.

Put the remains in a plastic container, seal it and apply a warning label. Wash the gloves under running water before removing them.

00-0 General

The following seals are most probably made from fluorocarbon rubber:

Seal rings for the crankshaft, camshaft, idler shafts.

O-rings, regardless of where they are installed. Orings for cylinder liner sealing are almost always made of fluorocarbon rubber.

Please note that seals which have not been exposed to high temperature can be handled normally.

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6

03-3 Specifications, Electrical

03-3 Specifications, Electrical

Electrical System

Technical Data

Switch, water in fuel

Voltage

Connector

Contact type

Sensor, fuel pressure

Voltage

Connector

Working pressure range

Pressure signal

Working temperature range

Type

Max tightening torque

Speed sensor, crankshaft / camshaft

Connector


Type

Max. tightening torque

24 V

2 pin

Closes when water is detected

5 V

3 pin

0–700 kPa (0-7 bar) (0–101.5 PSI)

0.5–4.5 V

-40 °C to +140 °C

Linear

30 ±5 Nm (22 ±3.7 lbf.ft.)

2 pin

-40 °C to +130 °C (-40 °F to +262 °F)

Inductive sensor

8 ±2 Nm (5.9 ±1.48 lbf.ft.)

Sensor, oil pressure

Voltage

Connector


Pressure signal


Type

Max tightening tourque

Sensor, coolant temperature

Voltage

Connector

5 V

3 pin

0–700 kPa (0-7 bar) (0–101.5 kPa)

0.5–4.5 V

-40 °C to +140 °C (-40 °F to +284 °F)

Linear

30 ±5 Nm (22 ±3.7 lbf.ft.)

Combination sensor, air inlet pressure / inlet manifold temperature

Voltage

Connector


Pressure signal


Type

5 V

4 pin

50–400 kPa (0.5-4 bar) (7.3–58.0 PSI)

0.5–4.5 V

-40 °C to +130 °C (-40 °F to +262 °F)

Linear/NTC

5 V

2 pin

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Type

Max. tightening torque

Switch, coolant level

Connector

Contact type

NTC

25 Nm (18.4 lbf.ft.)

2 pin

Closing with low coolant level

Alternator

Voltage

Connector

Capacity

Starter motor

Voltage

Connector

Capacity

(TAD1341–1345)

Sensor, crankcase pressure

Voltage

Connector


Pressure signal


Type

24 V

2 pin

80 A at 24 V

12 V

1 pol

5.5 kW

(7 kW)

5 V

3 pin

40–140 kPa (0.4–1.4 bar) (5.8–20.3 PSI)

0.5–4.5 V

-40 °C to +140 °C (-40 °F to +284 °F)

Linear

Combination sensor, oil level / temperature

Voltage

Connector


Type

Switch, piston cooling pressure

Connector

Contact type

5 V

4 pin

-40 °C to +140 °C (-40 °F to +284 °F)

NTC

2 pin

Closing for low piston cooling pressure

Combination sensor, air filter pressure/temperature

Voltage

Connector

Switch point


Type

Max 24 V

4 pin

-5 ±0.5 kPa (-50 ±5 mbar) (-0.73 ±0.073 PSI)

-40 °C to +100 °C (-40 °F to +244 °F)

NTC

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8


Engine Protection Map

TAD950-952VE, TAD1250-1252VE

Derate to engine protection map

Parameter

High coolant temperature

High oil temperature

High boost temperature

High air inlet pressure

(TAD950–952VE)

“Yellow lamp”

98 °C

(208.4 °F)

125 °C

(257.0 °F)

80 °C

(176.0 °F)

340 kPa

(49.3 PSI)


(TAD1250–1252VE)

Piston cooling pressure

425 kPa

(61.6 PSI)

Crankcase pressure When rapid increase of pressure

When switch is activated

Low oil pressure Limit

“Red lamp”

101 °C

(213.8 °F)

128 °C

(262.4 °F)

90 °C

(194.0 °F)

365 kPa

(52.9 PSI)

425 kPa

(61.6 PSI)

-

-

20 < limit

0 %

-

-

-

-

-

-

-

-

25 % 50 %

103 °C

(217.4 °F)

101 °C

(213.8 °F)

-

106 °C

(222.8 °F)

-

-

95 °C

(203.0 °F)

365 kPa

(52.9 PSI)

-

-

-

425 kPa

(61.6 PSI)

-

-

-

70 %

135 °C

(275.0 °F)

105 °C

(221.0 °F)

-

-

-

When rapid increase of pressure

When switch is activated

20 < limit

100 % Action

-

-

-

-

-

-

-

-

Hard derate

Hard derate

Hard derate

Hard derate

Soft derate

Soft derate

Soft derate

Hard derate

“Derate” means that the engine torque is limited. This means that engine speed is not affected or reduced as long as the torque limit isn’t reached.

“Hard derate” means that the engine quickly will decrease the torque.

“Soft derate” means that the engine will decrease the torque according to a function as a result of how much the alarm value has been exceeded.

Low oil pressure limit

TAD950-952VE

TAD1250-1252VE

500 rpm

160 kPa

(23.2 PSI)

500 rpm

160 kPa

(23.2 PSI)

1000 rpm

200 kPa

(29.0 PSI)

1000 rpm

180 kPa

(26.1 PSI)

1800 rpm

225 kPa

(32.6 PSI)

1900 rpm

225 kPa

(32.6 PSI)

2300 rpm

250 kPa

(36.3 PSI)

2300 rpm

250 kPa

(36.3 PSI)

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TAD1350-1355GE


Parameter



High inlet manifold temperature


High exhaust temperature

Crankcase pressure


98 °C

(208.4 °F)

125 °C

(257.0 °F)

80 °C

(176.0 °F)

500 kPa

(72.5 PSI)

580 °C

(1076.0 °F)

-


Low coolant level

Low oil pressure

-

-

Limit

“Red lamp”

> 103 °C

(217.4 °F)

> 130 °C

(266.0 °F)

>85 °C

(185.0 °F)

Forced shutdown

> 103 °C

(217.4 °F)

> 130 °C

(266.0 °F)

> 85 °C

(185.0 °F)

510 kPa

(74.0 PSI)

610 °C

(1130.0 °F)

> 510 kPa

(74.0 PSI)

> 610 °C

(1130.0 °F)



When switch is activated When switch is activated

Switch Switch

30 < limit 30 < limit

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TWD1643GE


Parameter



High inlet manifold temperature


High exhaust temperature

Crankcase pressure


98 °C

(208.4 °F)

125 °C

(257.0 °F)

80 °C

(176.0 °F)

500 kPa

(72.5 PSI)

580 °C

(1076.0 °F)

-


Low coolant level

Low oil pressure

-

-

Limit

“Red lamp”

> 103 °C

(217.4 °F)

> 130 °C

(266.0 °F)

>85 °C

(185.0 °F)

Forced shutdown

> 103 °C

(217.4 °F)

> 130 °C

(266.0 °F)

> 85 °C

(185.0 °F)

510 kPa

(74.0 PSI)

610 °C

(1130.0 °F)

> 510 kPa

(74.0 PSI)

> 610 °C

(1130.0 °F)



When switch is activated When switch is activated

Switch Switch

30 < limit 30 < limit

Oil pressure limit

y (kPa) z x (rpm)

P0014011

x Engine speed

y Oil pressure

z Oil pressure limit

10 47701632 10-2010

05-1 Safety Instructions

05-1 Safety Instructions

Safety Information

This Service Manual contains repair instructions, descriptions and technical data for products or product designs from Volvo Penta. Ensure that you are using the correct service manual.

Read the safety information below and the service manual section About this Workshop manual and Repair

instructions carefully before repair and service work is begun.

!

This symbol is used in the service manual and on the product, to call attention to the fact that this is safety information. Always read such information very carefully.

Safety texts in the manual have the following order of priority:

DANGER!

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING!

Indicates a hazardous situation which, if not avoided, could result in death or serious personal injury.

CAUTION!

Indicates a hazardous situation which, if not avoided, could result in minor or moderate personal injury.

IMPORTANT!

Is used to draw your attention to something that may cause minor damage or a minor malfunction to the product or property.

NOTICE! Is used to draw your attention to important information that will facilitate the work or operation in progress.

This symbol is used on our products in certain cases and refers to important information in the instruction book. Make sure that warning and information symbols on the engine are clearly visible and legible. Replace symbols which have been damaged or painted over.

A compilation of safety precautions that must be taken and risks which must be paid attention to is presented in the following pages.

47701632 10-2010 11


!

!

Immobilize the engine by turning off the power supply to the engine at the main switch

(switches) and lock it (them) in the off position before starting work. Post a warning notice at the main circuit breaker.

!

As a rule, all service operations must be carried out with the engine stopped. However, some work, such as adjustments, will require the engine to be running. Approaching an engine which is running is a safety risk. Bear in mind that loose clothing or long hair can fasten in rotating parts and cause serious personal injury.

!

Be aware of hot surfaces (exhaust pipes, turbos, charge air pipes, starting heaters etc.) and hot fluids in pipes and hoses on an engine that is running or has just stopped.

If work is done adjacent to a running engine, a careless movement or a dropped tool may in the worst case lead to personal injury.

!

Ensure that the warning symbols or information decals on the product are always clearly visible.

Replace decals which have been damaged or painted over.

!

Avoid getting oil on your skin! Protracted or repeated exposure to oil can cause skin to become dry. Irritation, dryness, eczema and other skin problems may then result. From a health standpoint, used oil is more dangerous than new. Use protective gloves and avoid oilsoaked clothes and rags. Wash regularly, especially before eating. Use suitable barrier creams to counteract drying out of the skin and to aid dirt removal.

Stop the engine and turn off the electrical supply at the main switch(es) before carrying out work on the electrical system.

!

!

!

Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out and system pressure will be lost. Open the filler cap slowly, and release the pressure in the cooling system if the filler cap or valve has to be opened, or if a plug or coolant hose has to be removed when the engine is hot.

!

Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before any work is begun.

Never start or operate the engine with the oil filler cap removed, because of the risk of oil ejection.

!

Never start the engine without installing the air filter. The rotating compressor turbine in the turbocharger can cause severe injury. Foreign objects entering the intake ducts can also cause mechanical damage. Install all protective covers before the engine is started.

Only start the engine in a well-ventilated space.

When running in a confined space, exhaust fumes and crankcase gases must be led away from the engine bay or workshop area.

The majority of chemicals e.g. engine and transmission oils, glycol, gasoline, and diesel oil, together with chemicals for workshop use such as degreasing agents, paints and solvents, are injurious to health. Carefully read the instructions on the product packaging! Always follow a product's safety directions, e.g. use of protective mask, glasses, gloves etc. Ensure that other personnel are not exposed to substances that are injurious to health. Ensure good ventilation. Handle used and leftover chemicals in the prescribed manner.

!

Clutch adjustments must be carried out with the engine stopped.

12 47701632 10-2010

!

!

Always use protective glasses or goggles when carrying out work where a risk of splinters, grinding sparks, splashes from acid or other chemicals is present. Your eyes are extremely sensitive; injury may cause blindness!

!

Never use start gas or similar products as a starting aid. They may cause an explosion in the inlet manifold. Danger of personal injury.

All fuels, as well as many chemicals, are flammable. Do not allow open flames or sparks in their vicinity. Gasoline, some thinners, and hydrogen gas from batteries are extremely flammable and explosive when mixed with air in the correct proportions. No Smoking! Ensure that the work area is well ventilated and take the necessary safety precautions before welding or grinding work is begun. Always ensure that there are fire extinguishers close at hand in the work area.

!

Batteries must never be exposed to open flames or electric sparks. Never smoke in the vicinity of the batteries; they generate hydrogen gas when charged, which is explosive when mixed with air. This gas is easily ignited and highly explosive. A spark, which can be caused by incorrect battery connection, is sufficient to cause a battery to explode and cause damage.

Do not touch the connections during start attempts. Sparking hazard! Do not lean over batteries.

!

Never transpose the positive (+) and negative

(-) battery posts when installing batteries. Such a transposition can result in serious damage to electrical equipment. Refer to the wiring diagram.

Always use protective goggles when charging and handling the batteries. Battery electrolyte contains sulfuric acid which is highly corrosive.

Should the battery electrolyte come into contact with unprotected skin, wash it off immediately using soap and copious amounts of water. If you get battery acid in your eyes, flush at once with copious amounts of water and seek medical assistance immediately.

!

!

!


Never start the engine with the valve cover removed. There is a risk of personal injury.

!

Stop the engine before working on the cooling system.

Marine engines: Close the sea cock / cooling water inlet valve before work on the cooling system is begun.

!

Make sure that oil, fuel-soaked rags, and used fuel and oil filters are stored in a safe manner.

Rags soaked in oil can spontaneously ignite under certain circumstances. Used fuel and oil filters are environmentally hazardous waste and must be handed to an approved waste management facility for destruction, as must any used lubrication oil, contaminated fuel, paint residue, solvents, degreasers and wash residue.

Never work alone when removing heavy components, even when using lifting devices such as locking tackle lifts. When using a lifting device, two people are usually required to do the work - one to take care of the lifting device and the other to ensure that components are lifted clear and not damaged during the lifting operations.

The existing lugs on the engine should be used for lifting. Always check that the lifting equipment used is in good condition and has the load capacity to lift the engine (engine weight including gearbox or extra equipment). For safe handling and to avoid damaging components fitted to the top of the engine, the engine must be lifted with a correctly adjusted lifting boom. All chains or wires must run parallel to each other and as perpendicular to the engine as possible.

If other equipment attached to the engine has altered its center of gravity, special lifting devices may be needed to obtain the correct balance for safe handling. Never perform any work on an engine that is only suspended from the lifting equipment.

47701632 10-2010 13


!

The components in the electrical and fuel systems on Volvo Penta products are designed and manufactured to minimize the risk of fire and explosion. The engine must not be run in areas where there are explosive materials.

!

Only use fuels and lubricating oils recommended by Volvo Penta. Refer to the Operator's

Manual for the product in question. Use of fuels that are of a lower grade may damage the engine, the injection pump and the injectors. On a diesel engine, low grade fuel can cause the control rod to bind and the engine to over-rev, with the risk of engine damage and personal injury as a result. Low fuel and oil grades may result in high service, maintenance and repair costs.

!

Fuel delivery pipes must not be bent or straightened under any circumstances. Cracks may occur. Damaged pipes must be replaced.

!

Exercise extreme caution when leak-detecting on the fuel system and testing the fuel injector nozzles. Use eye protection. The jet from a fuel nozzle has very high pressure and great penetration power. Fuel can force its way deep into body tissue and cause severe injury. There is a risk of blood poisoning (septicemia).

!

Never use a high-pressure washer for cleaning the engine.

Pay attention to the following when using a highpressure washer on components other than the actual engine: Never direct the water jet at seals, rubber hoses or electrical components.

14 47701632 10-2010

08-2 Special Service Tools

08-2 Special Service Tools

The following special tools are used when working on the engine. The tools can be ordered from AB Volvo

Penta by specifying the number indicated.

1

2

885675

3

4

5

P0006701

885675 Break out cable

Adapter cable for sensor test.

p0005125

9812519 Multimeter

Used for measurements.

P0008793


Adapter cable EMS2.

p0013275


Adapter cable for relay test.

9998482 Measuring tool

Gauge for connector on control unit.


Used with 9812519 Multimeter.

9998699 Break-out box

Used with 9990014 Break out cable.

p0008375

88820047 VODIA, diagnostic tool

Complete tool.

88890003 Press tool

Used for joining cables.

p0005128


For use with 9998699 Breakout box.


Used with 9812519 Multimeter to measure on the ECU.

88890058 Pliers

Jaw, used with 88890003 Press tool.

47701632 10-2010 15

08-2 Special Service Tools

88890028 Pin tool

Tool is included in 88890037

Extraction tool set.

16 47701632 10-2010

30-0 General

30-0 General

Design and Function

EMS 2 (Engine Management

System)

General Information

EMS 2 is an electronic system with CAN communication (Controller Area Network) for diesel engine control. The system has been developed by Volvo and includes fuel control and diagnostic function.

The system consists of a control unit, six unit injectors, a number of sensors that supply the control unit with measurements, sockets for diagnosis and functional checks. The engine can be connected to a communications interface consisting of a CAN link and a serial link.

CAN - Controller Area Network

The J1939 CAN link is responsible after all communication between the engine control unit (EMS 2) and a communication interface (such as CIU/DCU), except for diagnostics. Diagnostics are managed by the socalled J1708/J1587 link. The CAN link is much faster than the J1708/J1587 link and has been designed to connect to other components that support the SAE

J1939 protocol, such as instrument panels and transmissions.

If a fault develops on the CAN link, signals for the engine speed potentiometer, and the start and stop knobs are taken over by the J1708/J1587 link. However, instrument and indicator lamps are completely turned off.

If faults occur in both links, the engine starts to idle.

The only way to shut off the engine in this case is to use the auxiliary stop (AUX-STOP) placed on the engine’s left side.

47701632 10-2010 17

30-0 General

P0002060

P0002932

18

CIU - Control Interface Unit

The CIU is a “translator” between the CAN bus and the customer’s own control panel. This unit has two serial communication links, one fast and one slow.

The fast one is a CAN link that features a bus speed of 250 Kbit/s. All data regarding instruments, indicator lamps, contacts and potentiometers are controlled by this bus.

The slower J1708/J1587 link handles diagnostic information for, among other things, the flashing code. The

VODIA diagnosis tool also uses the J1708/J1587 link to communicate with the system.

DCU - Display Control Unit

DCU is a digital instrument panel that communicates with the engine control unit via the CAN link. DCU has several functions, such as:

Engine control

- Start, stop, speed control, pre-heating etc.

Monitoring

- Engine speed, boost pressure, boost temperature, coolant temperature, oil pressure, oil temperature, engine hours, battery voltage, instantaneous fuel consumption and fuel consumption (trip fuel).

Diagnostics

- Shows fault codes in text. Lists previous faults.

Parameter setting

- Idling speed, alarm limit for oil temperature/coolant temperature, droop.

- Preheating for ignition.

Information

- Information about hardware, software and engine identification.

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P0002061

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30-0 General

DU - Display Unit

The DU is an instrument panel which shows engine working values graphically on an LCD screen. It consists of an computerised unit for permanent installation in a control panel.

The display communicates via the CAN link. It is connected to the CAN link between the engine control unit and the CIU or DCU.

Monitoring

- Engine speed, boost pressure, boost temperature, coolant temperature, oil pressure, oil temperature, fuel pressure, engine hours, battery voltage, instantaneous fuel consumption and average fuel consumption (trip fuel).

Diagnostics

- Shows active fault codes in plain language.

Fuel control

The engine’s fuel requirement is analyzed up to 100 times per second (depending on engine rpm). The engine’s injection amount and injection timing is controlled electronically via fuel valves on the unit injectors.

This means that the engine always receives the correct volume of fuel in all operating conditions, which offers lower fuel consumption, minimal exhaust emissions etc.

The control unit checks and controls the unit injectors, to ensure that the correct volume of fuel is injected into each cylinder. It calculates and sets the injection angle.

The control is primarily performed using the speed sensors and the combined sensor for boost pressure/ boost temperature.

The control unit affects the unit injectors via an electronic signal to the unit injectors’ electromagnetic fuel valve, which can open and close.

When the fuel valve is open, fuel flows past, through the unit injectors’ holes and continuing out through the fuel channel. Fuel is not sprayed into the cylinder in this position.

When the fuel valve is closed, pressure is built up by the mechanically driven pump piston in the unit injector. When sufficient pressure has developed, fuel is injected into the cylinder via the unit injector’s injector section.

The fuel valve is re-opened and pressure in the unit injector decreases at the same time as the fuel injection to the cylinder stops.

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30-0 General

20

In order to determine when the fuel valve shall open or close, the control unit has access to signals from sensors and switch contacts.

Calculation of fuel quantity

The quantity of fuel to be injected into the cylinder is calculated by the control unit. The calculation determines the time that the fuel valve is closed (when the fuel valve is closed fuel is sprayed into the cylinder).

The parameters which govern the amount of fuel injected are:

• Demanded engine speed

• Engine protector functions

•

Temperature

• Boost pressure

Altitude correction

The control unit contains an atmospheric pressure sensor and an altitude compensation function for engines that operate at high altitude. This function limits the fuel volume in relation to ambient air pressure.

This is to prevent smoke, high exhaust temperature and to protect the turbocharger from overspeeding.

Diagnostic function

The task of the diagnostic function is to discover and localize any malfunctions in the EMS 2 system, to protect the engine and to inform about any problems that occur.

If a malfunction is discovered, this is announced by warning lamps, a flashing diagnostic lamp or in plain language on the instrument panel, depending on the equipment used. If a fault code is obtained as a flashing code or in plain language, this is used for guidance in any fault tracing. Fault codes can also be read by

Volvo’s VODIA tool at authorized Volvo Penta workshops.

In case of serious disturbances, the engine is shut down completely or the control unit decreases the power output (depending on the application). Once again, a fault code is set for guidance in any fault tracing.

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TAD950-952VE

1

2

3

Component location

4

5 6

30-0 General

15

14

7

10

9

8

13

12

11

P0013950

1 Coolant level sensor

2 Preheater

3 Unit injector

4 Crankcase pressure sensor

5 Extra stop

6 Sensor, air inlet pressure/intake manifold temperature

7 IEGR valve

8 Main relay

9 Oil level/temperature sensor

10 Fuel pressure sensor

11 Engine control unit (ECU)

12 Water in fuel sensor

13 Diagnostic outlet

14 Alternator

15 Main fuse, 10 A

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30-0 General

TAD950-952VE

22

21

16

19

20

P0013951

16 Coolant temperature sensor

17 Piston cooling pressure sensor

18 Oil pressure sensor

19 Starter motor

20 Starter motor relay

21 Speed sensor, crankshaft

22 Speed sensor, camshaft

18

17

22 47701632 10-2010

TAD1250-1252VE

1

2

3

4

5

6

7

30-0 General

21

9

8

20

19

18

17

16

15

10

14 13

12

11

P0013952


2 Speed sensor, camshaft

3 Unit injector (one for each cylinder)

4 Extra stop


6 Main relay


8 IEGR valve


10 Starter motor


12 Speed sensor, crankshaft

13 Connector for diagnostic tool, 6-pin

14 Engine interface, 8-pin connector



17 OiI level/temperature sensor



20 Main fuse, 10 A

21 Alternator

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TAD1250-1252VE

22 23

P0013953

22 Air filter indicator

23 Piston cooling pressure

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TAD1350-1355GE

1

16

2

3

4

5

6

15

14

13

11,12

10

STO

P

7

8

9

P0013972

1 Injector




5 IEGR valve


7 AUX stop

8 Main fuse

9 Main relay


11 Connector for diagnostic tool, 6-pin

12 Engine interface, 8-pin connector

13 OiI level/temperature sensor


15 Alternator

16 Pressure drop indicator/air temperature sensor

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TAD1350-1355GE

24

23

22

P0013973

21

20

19

17

18



19 Piston cooling oil pressure sensor


21 Starter motor

22 Flywheel position and rotation speed sensor

23 Camshaft position sensor


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13

TWD1643GE

16 1

15

2

3

4

5

6

11

10

9

8

7

12

P0013954

1 Coolant level switch

2 Unit injector (one for each cylinder)


4 Sensor, air filter pressure/air temperature

5 Wastegate regulator

6 Main fuse

7 Preheat relay

8 AUX stop

9 Main relay


11 Sensor, oil level/oil temperature


13 Alternator


15 Diagnosis tool connector


30-0 General

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30-0 General

TWD1643GE

23

24

22

P0013955


18 Exhaust temperature

19 Cold start valve

20 Camshaft position sensor

21 Starter motor

22 Battery connection points

23 Crankshaft sensor

24 Piston cooling switch

21 20

17

18

19

28 47701632 10-2010

P0013528

TAD1350-55GE

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TWD1643GE

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Component description

Starter motor

During starting, a gear on the starter rotor shaft is moved axially so that it engages with the ring gear on the engine’s flywheel. The axial movement as well as the activation of the starter motor is controlled by a solenoid on the starter motor.

The starter solenoid in turn is connected via the starter relay, which is activated when the starter key is turned to position III/the starter button is pressed.

Wastegate regulator

The TAD1350-55GE and TWD 1643 engine is equipped with a turbocharger with a wastegate valve. The wastegate valve controls the amount of exhaust gas flow which should pass through the exhaust turbine.

An electronically controlled regulation valve, wastegate regulator, which is controlled by the engine control unit controls the air pressure supplied to the wastegate valve. Boost air pressure taken from the inlet manifold is used to control the amount that the wastegate opens.

29

30-0 General

Alternator

The alternator is belt driven and is located at the left front of the engine.

30

P0013523

P0008694

P0008694

Unit injector

The unit injectors are located under the valve cover, mounted in the cylinder head.

The engine’s fuel requirement is analyzed up to 100 times per second (depending on engine rpm). The amount of fuel injected into the engine and the injection timing are electronically controlled via the unit injector’s solenoid controlled fuel valves. This means that the engine always receives the correct volume of fuel in all operating conditions, which offers lower fuel consumption, minimal exhaust emissions etc.

Speed sensor, crankshaft

The sensor is located in the left side of the flywheel housing.

The flywheel speed sensor is of the inductive type. It reads off the crankshaft position and speed from grooves in the flywheel. The signal is sent to the control unit, which calculates injection timing and fuel quantity.

Speed sensor, camshaft

The position sensor is located in the upper timing gear cover. The camshaft position sensor is of the inductivesensor type. The sensor reads off a cogged wheel with

7 cogs. The impulses from the camshaft sensor give the control unit information about which cylinder is in turn for injection and when it is performed.

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P0013515

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Air inlet pressure / inlet manifold temperature sensor

The air inlet pressure and intake manifold temperature are measured via a combined sensor positioned on the inlet pipe.

The air inlet pressure sensor measures absolute pressure, which is the sum of air inlet pressure and atmospheric pressure. The sensor supplies the control unit with a voltage signal proportional to the absolute pressure. The sensor receives a reference signal of 5 Volts from the control unit.

The intake manifold temperature sensor comprises a non-linear resistor, where the resistance is dependant on the temperature of the resistor body. The resistance drops as temperature rises.

Oil pressure sensor

The oil pressure is measured by a sensor located next to the control unit.

The sensor is fitted in the engine block so that measurements are performed in the lubrication systems main oil galley. The pressure signal is a voltage signal proportional to the pressure. The sensor reference voltage is 5 Volts.

IEGR

Internal exhaust gas recirculation, IEGR, is used for recirculation of exhaust gases. This for lowering the emissions from the engine. The IEGR control valve, is located on the cylinder head under the valve cover.

Oil level / temperature sensor

The sensor is located in the oil sump.

The purpose of the level sensor is to detect if the oil level becomes too low. A current is passed through the sensor and the voltage measured across it is then proportional to the oil level. An alarm signal is sent when the oil level is too low. The temperature sensor consists of a non-linear resistor, where the resistance is dependent on the temperature of the resistor body.

The resistance drops as temperature rises.

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P0013492 p0013478

Air filter pressure / temperature sensor

Air filter pressure and air filter temperature are measured by a combined sensor placed above the air filter.

The air filter pressure sensor measures absolute pressure, the sum of air filter pressure and atmospheric pressure. The sensor consists of a monitor that sends a signal to the control unit when the pressure in the air filter becomes too high.

The air filter temperature sensor consists of a non-linear resistor, where the resistance is dependant on the temperature of the resistor body. The resistance drops as temperature rises.

Crankcase pressure sensor

The sensor is located on top of the engine in the middle of the valve cover on the engine’s left side.

The pressure signal is a voltage signal proportional to the pressure. The sensor reference voltage is 5 Volts.

Switch, water in fuel

The switch is located in the lower part of the fuel prefilter.

It’s purpose is to detect water in the fuel system.The

switch comprises two copper electrodes, between which the resistance is measured. When the resistance drops below a certain limit, which indicates that there is water in the fuel, a warning message is sent to the control unit.

Exhaust temperature sensor

The exhaust temperature sensor consists of a Pt-200 sensor where the resistance changes depending on exhaust temperature. The resistance increases with rising exhaust temperature.

32

P0013504

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P0013963

P0013519

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Switch, coolant level

The switch is located in the expansion tank.

It’s purpose is to detect if the coolant level in the cooling system (expansion tank) becomes too low. The switch is a magnetically sensitive switch. A float located around the switch affects the switch differently depending on the coolant level. A alarm signal is sent when the coolant level is too low.

Cold start valve

In order to avoid boiling in the charge air coolers at different loads and coolant temperatures, the system is fitted with a cold start valve that is controlled by the

EMS2. The cold start valve is normally open i.e. without voltage supply the valve is open.

Preheat relay

In cold climate the intake air might need to be preheated. This is done by the preheater located on the intake manifold. The preheater is controlled by the

EMS2 via the pre-heat relay.

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30-0 General

TAD950-952VE,

TAD1350-1355GE,

TWD1643GE TAD1250-1252VE

Control unit EMS 2

The control unit checks and controls the unit injectors so that the correct amount of fuel is injected into each cylinder. It calculates and sets the injection angle.

The control is primarily performed using the speed sensors and the combined sensor for boost pressure/ boost temperature.

The EMS 2 system processor is located in the control unit, where it is protected from moisture and vibration.

The processor receives information continuously about:

• engine speed

• camshaft position

• boost pressure

• boost temperature

• coolant temperature

• oil pressure

• oil temperature

• oil level

• crankcase pressure

• piston cooling pressure

• water in fuel

• fuel pressure

• coolant level

• air filter pressure

• air filter temperature

Information from the sensors provides exact information about current operation conditions and allows the processor to calculate the correct fuel volume, check engine status etc.

Coolant temperature sensor

The sensor is located in the left rear part of the cylinder head.

The sensor senses the coolant temperature and sends the information to the control unit. The sensor comprises a non-linear resistor, where the resistance is dependant on the temperature of the resistor body.

The resistance drops as temperature rises.

p0004941

34 47701632 10-2010

30-0 General

Switch, piston cooling

A valve is installed in the oil filter bracket which opens or closes the oil supply for piston cooling, depending on oil pressure. If the oil pressure is below 250 kPa

(36.3 PSI) (TAD950-952VE) or 300 kPa (43.5 PSI)

(TAD1250-1252VE), the valve closes the oil supply for piston cooling.

The piston cooling pressure is monitored by a pressure monitor. The output signal from the pressure monitor can only have two distinct positions, on/off, in the same way as a relay output. The monitor is supplied with current from the engine control unit. A pre-set pressure limit of 150 kPa (21.8 PSI) determines when the monitor switches on. The monitor opens if the pressure exceeds this value.

At idle, the monitor can be closed without a fault code being set.

Fuel pressure sensor

The sensor measures fuel pressure and is located on the fuel filter bracket. The sensor is an active sensor, i.e. the sensor requires a supply voltage of +5 Volt. The sensor provides an output signal whose voltage is proportional to the pressure that the sensor measures.

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P0013966

36

30-0 General

Repair Instructions

General advice on working with EMS engines

The following advice must be followed to avoid damage to the engine control unit and other electronics.

IMPORTANT!

The system must be disconnected from system voltage (by cutting the current with the main switch) and the starter key(s) must be in the 0 position when the engine control unit connectors are disconnected or connected.

• Never disconnect the current with the main switches when an engine is running.

• Never undo a battery cable when the engine is running.

• Turn the main switches off or disconnect the battery cables during quick charging of the batteries.

NOTICE! During normal trickle charging, it is not necessary to turn the main switches off.

• Only batteries may be used for start help. A help start device can produce a very high voltage and damage the control unit and other electronics.

• If a connector is disconnected from a sensor, be very careful to avoid allowing the contact pins to come into contact with oil, water or dirt.

Electrical Welding

1 NOTICE! Cut the current with the main switch.

IMPORTANT!

The system must be disconnected from system voltage when the engine control unit connectors are disconnected or connected.

2 Undo the two connectors from the engine control unit before any electrical welding starts. Turn the locking arm down at the same time as the connector is pulled outwards.

3 Disconnect all connections to the alternator.

Connect the welder earth clamp to the component to be welded, or as close as possible to the weld site. The clamp must never be connected to the engine or in such a way that current can pass through a bearing.

IMPORTANT!

After welding is completed, the disconnected components, such as alternator cables and battery cables must be connected in the correct order.

The battery cables must always be connected last.

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Engine Control Unit (ECU), Replace


IMPORTANT!

The system must be disconnected from system voltage when the engine control unit connectors are disconnected or connected.

2 Remove the two connectors from the engine control unit. Turn the locking arm down at the same time as the connector is pulled outwards.

3 Change the engine control unit.

4 If the new engine control unit has recently been programmed:

Start the engine and check whether any fault codes related to the engine control unit occur.

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30-0 General

Reprogramming a control unit

IMPORTANT!

The CHASSIS ID number must be readily available to allow the software to be downloaded.

Action:

1 Log in to Volvo Penta Partner Network’s website:

www.vppn.com

2 Choose “VODIA” in the left-hand menu.

3 Choose “ECU programming” in the left-hand menu.

4 Follow the instructions under “Download software”.

Choose the control units to be reprogrammed and click the “Download” button.

The software for the control units is now downloaded to the PDA

(1)

.

5 Take a look under “Settings”, “Software information” in VODIA to check that the software has been downloaded.

6 Connect the VODIA to the engine (control unit) to be programmed.

7 Start with the engine control unit.

Select “Engine with mounting and equipment” in the VODIA menu.

Select “MID 128 Control unit, programming”.

VODIA will guide you through the entire programming process.

8 The next control unit is the vehicle ECU.

Select “Electrical system and instruments” in the VODIA menu.

Select “MID 144 ECU, programming”.

VODIA will guide you through the entire programming process.

9 NOTICE! Programming must be reported back to Volvo Penta within 28 days.

Log in to Volvo Penta Partner Network’s web site (www.vppn.com).


11 Choose “Report software” in the left-hand menu.

12 Follow the instructions for “Report software/parameter”.

Click “Report software/parameter”.

38

1. PDA = “Personal Digital Assistant” (palmtop computer).

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Programming an empty control unit

When a new engine control unit is installed, where no software has been downloaded, the control unit must be programmed.

The new control unit must have the same part number as the old control unit. If the control units do not have the same part number, it will not be possible to program the new control unit until a “Conversion kit” has been ordered from Volvo Penta.

If the control units have the same part number, the new control unit can be programmed as usual. Please refer

to Reprogramming a control unit page 38.

If the part numbers do not coincide – proceed as possible:

1 Have both part numbers available.

2 Log in to Volvo Penta Partner Network’s web site:

www.vppn.com


4 Choose “Conversion kit” in the left-hand menu. A new page, “Conversion kit / Accessory kit”, opens up.

5 Click the text “Available conversions kits” which is shown in bold face.

6 A new window opens. Follow the instructions given in the window.

7 Return to the “Conversion kit / Accessory kit” page and follow the instructions to order a new “conversion kit”.

8 Volvo Penta’s database is now updated. It can take about a minute before a confirmation is sent.

9 Programing of the control unit can now start. Please

refer to Reprogramming a control unit page 38.

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30-0 General

40

Fault tracing of cables and connectors

Tools:

9812519 Multimeter

9998482 Measuring tool

Check all connectors visually

Check the following:

• Look for oxidation which can impair contact in connectors.

• Check that terminals are undamaged, that they are correctly inserted into their connectors, and that the cable is correctly terminated in the terminal.

• Check that there is good mechanical contact in the connector. Use a loose pin to check this.

IMPORTANT!

The multi-pin connectors for the engine control unit must only be checked with 9998482 Measuring tool.

• Carefully insert 9998482 Measuring tool into the multi-pin connector. Pull and push the connector in and out a few times and feel whether the terminal socket grasps the tool. If the terminal socket does not grasp, or if it feels slack, the connection pins

should be changed. Please refer to Joining electrical

cables for connectors page 42. Check the secon-

dary locking in the connector.

• If possible, shake the cables and pull the connectors during measurement to discover whether the cable harness is damaged.

• Check that the cables are not damaged. Avoid clamping cables in tight bends close to the connector.

• Check the function of the secondary locking.

Contact problems

Intermittent contact or temporary recurring faults can be difficult to fault trace, and are frequently caused by oxidation, vibration or poorly terminated cables.

Wear can also cause faults. For this reason, avoid disconnecting a connector unless it is necessary.

Other contact problems can be caused by damage to pins, sockets and connectors etc.

Shake cables and pull connectors during measurement, to find where the cable is damaged.

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Contact resistance and oxidation

Resistance in connectors, cables and junctions should be approx. 0 Ω. A certain amount of resistance will occur, however, because of oxidation in connectors.

If this resistance is too great, malfunctions occur. The amount of resistance that can be tolerated before malfunctions occur varies, depending on the load in the circuit.

Open circuit

Possible reasons for faults could be chafed or broken cables, or connectors which have come undone.

Use the wiring schedule to check the cables which are relevant to the function. Start off with the most probable cable in the circuit.

Check the following:

• Disconnect the relevant connector at each end of the cable harness.

• Use 9812519 Multimeter to measure the resistance between the ends of the cable.

Nominal value ~ 0 Ω.

• If possible, shake the cables and pull the connectors during measurement to discover whether the cable harness is damaged.

• Check the next cable system in the wiring schedule if no fault has been found.

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P0007180

42

Joining electrical cables for connectors

Tools:

88890003 Press tool

88890028 Pin tool

88890058 Pliers

Repair kit:

1078054

1 Disconnect the connector from the engine control unit or from the power supply unit, please refer to

Engine Control Unit (ECU), Replace page 37.

Undo the connector, to gain access to the cable leading to the pin which is to be changed.

2 Undo the pin catch.

3 Remove the pin with 88890028 Pin tool.

NOTICE! Only remove one pin at a time.

4 Cut off the cable and the pin which is to be changed.

Join the cable with the new one, using repair kit no.

1078054. Use 88890003 Press tool with

88890058 Pliers.

5 Carefully heat the joint with a hot air gun, to make the insulation shrink and seal tightly.

6 Put the pin back in the right place in the connector before removing the next pin, if several pins are to be changed. Check that the locking tongue locks the pin in the connector.

7 Install the cables with insulation and tie wraps in the connector, in the reverse order to disassembly.

8 Install the connector in the reverse order to disassembly.

9 Check that the connector and the mating connector on the engine control unit or power supply unit are clean and dry.

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10 Join up the multi-pin connector. Please refer to

Engine Control Unit (ECU), Replace page 37 for

advice on joining up the connector.

11 Start the engine and check carefully that no fault codes occur.

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30-0 General

Checking the starter motor voltage

Tools:

9812519 Multimeter

General

If battery voltage falls below 24.7 V*, the starter motor will not be able to crank the engine at normal speed.

A fully charged battery has an open circuit voltage of about 25.4 V.

NOTICE! * Measured on the batteries.

Voltage measurement, check

1 Check that the battery voltage is at least 24.7 V when unloaded by using 9812519 Multimeter to measure between the battery poles.

2 Turn the main switch on.

3 Check that the voltage between terminal B+ on the starter motor and battery negatives connection point is the same as the battery voltage.

P0008397

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Generally about alternators:

The voltage output from an alternator must be limited to prevent the elecrolyte in the battery to evaporate.

The alternator output is regulated (limited) by the voltage regulator in the alternator. The maximum current that the alternator can deliver at regulated voltage output depends on the alternator revolution. When the engine is started an excitation current is needed to

“wake up” the alternator.

NOTICE! It is the consumers (batteries included) which decides the output current from the alternator.

Measurements

1 Engine off.

2 Use 9812519 Multimeter to do a voltage measurement over the battery. The nominal voltage over a full loaded battery is approx. 25.4 V.

3 Engine on. Run at 1500 rpm.

4 Use 9812519 Multimeter to do a voltage measurement over the battery and also over the alternator. The nominal charging voltage over the battery should be approx. 27.8-28.6 V.

Checking the charging system

Tools:

9812519 Multimeter

Fault tracing charging system

Battery check

1 Check that all connectors at the battery are correctly assembled.

2 Check the condition of the cables to the battery.Look for oxidation.

3 Check the water level in the battery.

4 Check, if possible, the specific gravity of all cells.

when no charge

1 Check the alternator belt tension.

2 Check that all connectors at the alternator and at the battery are correctly assembled.

3 Check the condition of all cables in the charging system.

4 Regulator fault. Replace regulator.

when undercharge

1 Check the alternator belt tension.

2 Check that all connectors at the alternator and at the battery are correctly assembled.

3 Check the condition of all cables in the charging system.

4 Regulator fault. Replace regulator.

when overcharge

1 Probably regulator fault. Replace regulator.

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Alternator fault tracing

Checking the brushes and the regulator

• NOTICE! Cut the current with the main switch.

• Remove all connectors on the alternator. B+, B-, etc.

• Remove the plastic cover over the diodes. The plastic cover is fixed with two nuts on B1+, B2+, and a pozidrive screw.

• Remove the three screws that holds the brushes and the regulator.

Checking the brushes

• Measure the length of the brushes between the brush mating surface and the brush holder. If any brush is damaged the brushes should be replaced.

Checking the regulator

• Set 9812519 Multimeter to diode measurement.

•

Connect the probes between the brushes. Check that there is no short circuit.

•

Switch the probe points and check that there is no short circuit.

•

NOTICE! If a regulator fault is suspected install a new regulator and test operate the charge system.

Checking the rotor

• Set 9812519 Multimeter to diode measurement.

• Connect one probe to each slip ring. The multimeter should show low resistance but not 0 ohm (short circuit) or infinity (open circuit).

• Check that the slip rings do not have any burn marks or other damage.

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Short circuit test the rotor

1 Set the 9812519 Multimeter to diode measurement.

2 Connect the probes between one of the slip rings and the stator body. The multimeter should indicate

OL otherwise the rotor has a short circuit.

Manual fault tracing in bus cables

Tools:

9812519 Multimeter

IMPORTANT!

Cut the current with the main switch before the cables are disconnected.

Use the multimeter to check the bus cables. The conductors in the bus cables should not be in contact with each other.

Disconnect a bus cable at each end and measure the resistance between the pins to check this. The multimeter should show infinite resistance between each pin. If the resistance is less than infinite, there is a fault.

Measuring the engine cables

Two types of measurements are done on the engine cable harness, both resistance measurement and voltage measurement.

The measurements are done to ensure that no open circuits or short circuits occur.

If there is an open circuit, the resistance is infinite, and if there is a short circuit, it is close to zero. The resistance values given in the workshop manual are approximate, and should be regarded as guidelines.

NOTICE! When resistance measurement is done, the engine should be stopped and system voltage should be cut off with the main switch.

All resistance measurement is done at +20 °C (68 °F) and with a cold engine.

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Malfunctions

Fault code information

• MID (“Message Identification Description”):

The MID consists of a number which designates the control unit that sent the fault code message.

(e.g. the engine control unit).

• PID (“Parameter Identification Description”):

The PID consists of a number that designates a parameter (value) to which the fault code relates

(oil pressure, for example).

• PPID (“Proprietary PID”):

The same as the PID, but this is a Volvo-specific parameter.

• SID (“Subsystem Identification Description”):

The SID consists of a number that designates a component to which the fault code relates (tachometer, for example).

• PSID (“Proprietary SID”):

The same as the SID, but this is a Volvo-specific component.

• FMI (“Failure Mode Identifier”):

FMI indicates the type of fault (please refer to the FMI table below).

• SPN

Suspect Parameter Number

FMI table

SAE standard

FMI Display text

0

“Value too high”

1

“Value too low”

2

“Faulty data”

3

“Electrical fault”

4


5


6


7

“Mechanical fault”

8

“Mechanical or electrical fault”

9

“Communication fault”

10

“Mechanical or electrical fault”

11

“Unknown fault”

12

“Component fault”

13

“Faulty calibration”

14

“Unknown fault”

15

“Unknown fault”

SAE text

Data valid but above normal operational range.

Data valid but below operational range.

Data erratic, intermittent, or incorrect

Voltage above normal or shorted high.

Voltage below normal or shorted to lower voltage.

Current below normal or open circuit.

Current above normal or short circuit to battery negative

Mechanical system not responding properly

Abnormal frequency, pulse width, or period

Abnormal update rate

Abnormally large variations

Unidentifiable error.

Faulty device or component

Calibration value out of range.

Special instructions

Reserved for future use

SAE standard

FMI Help

2

Short circuit to battery voltage, injector high voltage side

3

Short circuit to battery voltage, injector low voltage side

4

Short circuit to battery negative, injector low voltage or high voltage side

9

Open circuit in injector circuit.

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30-0 General

General advice

NOTICE! The following must be done before fault tracing continues, to avoid changing functional sensors:

If there is an active / inactive fault code

Remove the connector from the sensor. Check that there is no oxidation and that the connector pins are not damaged.

If there is a fault, please refer to the instructions in Fault

tracing of cables and connectors page 40.

NOTICE! Some fault codes become inactive when the engine is stopped. Start the engine to check whether the fault code is still inactive with the engine running.

After an action with the connector

Put the connector back. Check if the fault code becomes inactive.

Check faults that could be related to that specific sensor.

If the fault remains, measure the cables and sensors to check them, as instructed.

Network

The system has two types of communication buses.

CAN

A data link (CAN bus) links the nodes to each other.

CAN (“Controller Area Network”) is an industrial standard for distributed systems.

The CAN bus consists of a pair of copper conductors which are twisted 30 times per meter. The nodes communicate via the CAN bus and they form a network together, which exchanges information and benefits from each other’s services.

The CAN bus is a serial bus and is the primary control bus.

J1587

The communication bus, J1587, is also used for accessories and for diagnostics.

This is a serial bus in accordance with standard SAE

J1708.

49

30-2 Fault Tracing

30-2 Fault Tracing

Fault Codes

MID 128, PID 45 Inlet air heater status

FMI 3 – Voltage above normal or shorted high

Fault code explanation:

Fault indication:

Faulty sensor / Faulty sensor circuit

DCU: Engine warning in DCU display.

CIU: Flash code

Symptom:

Conditions for fault code:

Possible reason:

Suitable action:

Flash code

Electrical fault: 5.4

Value fault: None

Preheat relay never activated. White smoke for cold start.Start problems in cold climate.

The voltage on pin B25 or on pin B7 on the EMS2 deviates from normal voltage value.

Short circuit to battery voltage in cable harness between EMS2 and preheat relay.

1 Check all connections on the preheat relay and all cables between

EMS2 and preheat relay.

FMI 4 – Voltage below normal or shorted to lower voltage





CIU: Flash code

Symptom:




Flash code


Value fault: None

Induction air is hot. Preheat relay is impossible to turn off. Preheat fuse will break.

The voltage on pin B25 or on pin B7 on the EMS2 deviates from normal voltage value.

Short circuit to battery negative in cable harness between EMS2 and preheat relay.



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30-2 Fault Tracing

FMI 5 – Current below normal or open circuit





CIU: Flash code

Symptom:




Flash code


Value fault: None

Preheat relay never activated. White smoke for cold start.Start problems in cold climate.

The current through pin B25 or through pin B7 on the EMS2 deviates from normal current value.

Open circuit in cable harness between EMS2 and preheat relay.



2 Check the contact pressure in socket 25 and in socket 7 in the engine connector B.

p0013470

A

(+)57,

25

60

7

OR

R / BL

BN

B

EMS2

p0013471

A Connector B

B Junction point

C Preheat relay

C

Cable description

In cold climate the intake air might need too be preheated. This is done by the preheater located on the intake manifold. The activation of the preheater is controlled by the EMS2 via the preheat relay. EMS2 pin

B25 activates the preheat relay. A sense wire is connected between the preheater relay output and B7.

The sense wire checks that the preheat element and the preheat fuse are not damaged.

Measurements

Checking the wiring page 125

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30-2 Fault Tracing

MID 128, PID 94 Fuel Delivery

Pressure

FMI 1 – Data valid but below operational range



Fuel pressure is too low.

DCU: Engine warning in DCU display

CIU: Flash code

Symptom:



Flash code


Value fault: 3.8

None.

The fuel pressure alarm depends on the engine revolution.

1 Check the fuel level.

2 Open all fuel cocks and check that no leakage occurs.

3 Change all fuel filters. (pre- and fine filter)

4 Check that no fuel hose is squeezed or folded.

5 Check the fuel sensor by control measuring the fuel pressure. (see workshop manual)

6 Remove and clean the pressure release valve in the fuel feed pump.






CIU: Flash code

Symptom:




Flash code


Value fault: 3.8

None.

The voltage on pin B16 on the EMS2 is more than 4,77 Volt.

• Open circuit in the sensors negative cable.

• Short circuited fuel sensor signal cable to 5V voltage or to battery voltage.

• Faulty sensor.

1 Check the cable harness between the fuel sensor and EMS2.

2 Check the contact pressure in socket 18 in the engine connector B.

3 Check the sensor.

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30-2 Fault Tracing






CIU: Flash code

Symptom:




Flash code


Value fault: 3.8

None.

The voltage on pin B16 on the EMS2 is less than 0.07 Volt.

• Open circuit in fuel sensor 5V supply cable.

• Open circuit in fuel sensor signal cable.

• Short circuited sensor signal cable to battery negative.

• Faulty sensor.

1 Check the cable harness between the fuel sensor and EMS2.

2 Check the contact pressure in socket 16 and 17 in the engine connector

B.

3 Check the sensor.

P0002552

A

(+) 17

(-) 18

R

SB

16

GN /BL

B

EMS2

3

SB

R / BL

5

1

2

4

C

4 1

P

2

P

D

-

+ p0013472

A Connector B

B Fuel press switch

C Fuel pressure

D Fuel bleeding pump


The sensor is an active sensor, i.e. the sensor must receive operating voltage. Pin 17 on the engine control unit (EMS2) connector B provides pin 1 on the sensor with an operating voltage of +5 Volt. Pin 4 on the sensor is connected to battery negative via pin 18 on the

EMS2. The output signal from the pressure sensor, pin

2 on the sensor to pin 16 on the EMS2, is a voltage signal that is proportional to the fuel pressure. The output signal is linear within the sensors working range.

Some engines has a fuel bleeding pump. The fuel bleeding pump is used when the fuel system has to be bled.

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30-2 Fault Tracing

3

2

5

4

1

0

0 100 200 300 400 500 600 700 p0013477

Oljetryck, kPa

Component specification

Working range: 0 – 7 bar = 0 – 700 kPa

Supply voltage: 5,00 +/- 0,25 VDC

Nominal output voltage at 25 °C and at supply voltage

5,00 VDC:

0,5 VDC @ 0 bar = 0 kPa

4,5 VDC @ 7 bar = 700 kPa

Measurements

Checking supply cable, fuel sensor page 125

Checking negative cable, fuel sensor page 126

Checking the signal cable for interruption or shortcircuit page 127

Checking fuel pressure sensor page 128

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MID 128, PID 97 Water in fuel indicator

FMI 0 – Data valid but above normal operational range



Water in fuel.


CIU: Flash code

Symptom:



Flash code


Value fault: 2.1

None.

• Water in the fuel trap has been detected.

• Short circuit between both cables to the water in fuel switch.

1 Empty the water trap.

2 Check the water in fuel switch.

3 Check the cable harness between water in fuel switch and EMS2.




Faulty monitor / Faulty monitor circuit


CIU: Flash code

Symptom:




Flash code


Value fault: 2.1

None.

The voltage potential on B8 is too high.

The cable connected to B8 is short-circuited to battery voltage.

1 Check the cable harness between water in fuel switch and EMS2.

p0013478

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30-2 Fault Tracing

A

10

SB

EMS2

p0013479

8

Y

A Connector B

B Water in fuel

2

3

B


A sensor is located in the water trap under the fuel filter.

Its task is to detect whether there is water in the fuel.

The EMS 2 senses the voltage drop between the pins

B10 and B8. The pins are in contact with the fuel. When there is no water in the fuel, the voltage is 0,8 x battery voltage. If there is any water in the fuel, voltage will drop.

The sensor is connected via pin B10 on the engine control unit to battery negative.

Measurements

Checking supply cable, water in fuel switch page 129

Checking negative cable, water in fuel switch page 130

Checking water in fuel switch page 130

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30-2 Fault Tracing

MID 128, PID 98 Engine oil level




Oil level too low.


CIU: Flash code

Symptom:


Flash code


Value fault: 5.7

Warning indication.

1 Check the oil level in the engine.

2 Check that no oil leakage occurs.

3 Check the oil level sensor.




Faulty sensor / Fault in sensor circuit


CIU: Flash code



Flash code


Value fault: 5.7

• Open circuit in the oil level sensor 5V supply cable.

• Faulty sensor.

1 Check the cable harness between the sensor and the EMS2.


B.

3 Check the sensor.

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30-2 Fault Tracing b

3

10

GN/SB

SB

4

GN/W a

P0008588

EMS2

31

GR/OR a Connector A b Connector B c Oil temperature and level

4

1

2 3 c


The oil temperature and the oil level sensor is a combined sensor. The oil level sensor, pin1, is fed a current pulse of approx. 250mA during approx. 600ms and the voltage output will be sampled three times during this time. To obtain the oil level the oil temperature has to be used as a reference due to that the oil level output voltage will alter depending on the oil temperature.

Measurements

Checking oil level sensor page 131

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30-2 Fault Tracing

MID 128, PID 100 Engine oil pressure




Oil pressure is too low.


CIU: Flash code

Symptom:




Flash code


Value fault: 6.6

Power is reduced due to error torque map if the engine protection parameter is activated.

Oil pressure depends on the engine revolution. Oil pressure exceeds the set value of the engine protection parameter.

• Too low engine oil level.

• Blocked oil filter.

• Oil leakage.

• Faulty oil pressure sensor.

1 Check the engine oil level and the quality of the oil.

2 Change engine oil and oil filter to prevent blocked oil filter.

3 Check that no engine oil leakage occurs.

4 Check the sensor by control measuring the engine






CIU: Flash code




Flash code


Value fault: 6.6



• Short circuit between signal cable and 5V supply to oil pressure sensor.

• Faulty sensor.

1 Check the cable harness between the oil pressure sensor and EMS2.


3 Check the sensor.

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30-2 Fault Tracing






CIU: Flash code




Flash code


Value fault: 6.6


• Open circuit in 5V supply cable to oil pressure sensor.

• Open circuit in signal cable to oil pressure sensor.

• Short circuit between signal cable and battery negative to oil pressure sensor.

• Short circuit between the sensor 5V supply cable and the sensor negative cable.

• Faulty sensor.

1 Check the cable harness between the oil pressure sensor and EMS2.


A and in socket 11 in engine connector B.

3 Check the sensor.

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Conn. A

(black)

(+) 7

(-) 11

R

SB

EMS2

Conn. B

(black)

11

BL / OR

4 1

P2

30-2 Fault Tracing


The sensor which measures the oil pressure is an active sensor, i.e. it must have operating voltage.

The engine control unit, connector A, pin 7, supplies the sensor, pin 1 with +5 Volt. The sensor, pin 4, is connected to battery negative via the engine control unit, connector A, pin 11.

The output signal from the pressure sensor, pin 2, to the engine control unit, connector B, pin 11, is a voltage signal which is proportional to the oil pressure (after the oil filters). The output signal is linear within the sensors working range.

P0013480 a Connector A b Connector B c Oil pressure

5

4

3

2

1

0

0 100 200 300 400 500 600 700 p0013477

Oljetryck, kPa


Working range: 0 – 7 bar = 0 – 700 kPa.

Supply voltage: 5,00 +/- 0,25 VDC.


5,00 VDC:

0,5 VDC

≈ 0 bar = 0 kPa

4,5 VDC

≈ 7 bar = 700 kPa

Measurements

Checking supply cable, oil pressure sensor page 132

Checking negative cable, oil pressure sensor page 132

Checking signal cable, oil pressure sensor page 133

Checking oil pressure sensor page 133

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30-2 Fault Tracing

MID 128, PID 105 Intake manifold temperature




Inlet manifold temperature is too high


CIU: Flash code

Symptom:




Flash code


Value fault: 6.2

Engine is derated if the engine protection parameter is activated.

Inlet manifold temperature exceeds the set value of the engine protection parameter.

• Engine temperature is too high.

• High surrounding temperature. (Faulty air inlet temperature sensor, only on TAD1250-1252VE and TAD1350-1352GE).

• Dust or dirt on the outside of the intercooler and the radiator.

• Faulty inlet manifold temperature sensor.

1 Check that the engine temperature is normal.

2 Check the air inlet temperature sensor, only on TAD1250-1252VE and

TAD1350-1352GE.

3 Clean the intercooler and the radiator.

4 Check the inlet manifold temperature sensor.






CIU: Flash code




Flash code


Value fault: 6.2

The voltage on pin A47 on the EMS2 is less than 0.07 Volt.


• Faulty sensor.

1 Check the cable harness between the inlet manifold temperature sensor and EMS2.

2 Check the sensor.

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CIU: Flash code




Flash code


Value fault: 6.2

The voltage on pin A47 on the EMS2 is more than 4,95 Volt.

• Open circuit in inlet manifold temperature signal cable.

• Faulty sensor.

1 Check the cable harness between the inlet manifold temperature sensor and EMS2.

2 Check the contact pressure in socket 47 in engine connector A.

3 Check the sensor.

a

P0007209 a Connector A b Intake manifold temperature

b

47701632 10-2010


The inlet manifold temperature sensor consists of a thermistor which forms a closed circuit with an internal resistor in the engine control unit (EMS2). The thermistor resistor changes in a non-linear manner, depending on the inlet manifold temperature. The

EMS2 provides the circuit with a reference voltage of

+5 Volt. The EMS2 measures the voltage drop over the thermistor via pin 47 and pin 11 on the EMS2. Pin 1 on the sensor is connected to battery negative via pin 11 on the EMS2. When the inlet manifold air is cold, the thermistor resistance is high and the EMS2 senses a high voltage drop. As the inlet manifold air warms up, the resistance in the thermistor falls and the voltage drop across it falls.

Please refer to the table, “resistance/temperature” in this fault code chapter.

Measurements

Checking signal cable voltage, inlet manifold (pressure/)temperature sensor page 134

Checking negative cable, inlet manifold pressure/temperature sensor page 135

Checking the sensor cable for open circuit or shortcircuit page 136

Checking inlet manifold temperature sensor page 137

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30-2 Fault Tracing

MID 128, PID 106 Air inlet pressure




Air inlet pressure is too high.


CIU: Flash code

Symptom:




Flash code


Value fault: 3.5


Air inlet pressure exceeds the set value of the engine protection parameter.

• The wastegate does not function properly.

• Faulty air inlet pressure sensor.

• Wrong turbo compressor unit according to the engine specification.

1 Check the wastegate functionality. (see workshop manual Group

21-26)

2 Check the air inlet pressure sensor by control measuring the air inlet pressure using a measuring tap (see workshop manual Group 21-26)

3 Check that the turbo compressor unit is in according the engine specification.






CIU: Flash code

Symptom:




Flash code


Value fault: 3.5

Engine smokes more than normally during acceleration or load increase.

The voltage on pin A22 on the EMS2 is more than 4,77 Volt.


• Short circuited sensor signal cable to 5V voltage or battery voltage.

• Faulty sensor.

1 Check the cable harness between the air inlet pressure sensor and

EMS2.

2 Check the contact pressure in socket 11 in engine connector A.

3 Check the sensor.

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30-2 Fault Tracing






CIU: Flash code

Symptom:




Flash code


Value fault: 3.5

Engine smokes more than normally during acceleration or load increase.


• Open circuit in air inlet pressure signal cable.

• Open circuit in 5V supply cable to sensor.

• Short circuited air inlet pressure signal cable to sensor negative cable.

• Faulty sensor.

1 Check the cable harness between the boost pressure sensor and

EMS2.

2 Check the contact pressure in socket 7 and 22 in engine connector A.

3 Check the sensor.

a

P0007209 a Connector A b Intake manifold temperature

b


The sensor is an active sensor, i.e. the sensor must receive operating voltage. The air inlet pessure sensor measures the absolute pressure, which is the sum of the air inlet pressure and atmospheric pressure (300 kPa thus corresponds to a boost pressure of 200 kPa when atmospheric pressure is 100 kPa).

Pin 7 on the engine control unit (EMS2) connector A provides pin 3 on the sensor with an operating voltage of +5 Volt. Pin 1 on the sensor is connected to battery negative via pin 11 on the EMS2. The output signal from the pressure sensor, pin 4 on the sensor to pin 22 on the EMS2, is a voltage signal that is proportional to the air inlet pressure. The output signal is linear within the sensors working range.

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30-2 Fault Tracing

P0013490


Working range 0,5 – 4,0 bar = 50 – 400 kPa

Supply voltage: 5,00 +/- 0,25 VDC


5,00 VDC:

0,5 VDC

≈ 0,5 bar = 50 kPa

4,5 VDC

≈ 4 bar = 400 kPa

Measurements

Checking supply cable, inlet manifold pressure sensor page 138

Checking negative cable, inlet manifold pressure/temperature sensor page 135

Checking signal cable, inlet manifold pressure sensor page 138

Checking air inlet pressure sensor page 139

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MID 128, PID 107 Air filter pressure drop




Air pressure is too low.


CIU: Flash code

Symptom:



Flash code


Value fault: 5.6

None.

Blocked air filter.

1 Change the air filter.






CIU: Flash code

Symptom:




Flash code


Value fault: 5.6

None.

The voltage on pin A29 on the EMS2 is too high.

• Short circuit between the air pressure switch signal cable and battery voltage.

• Faulty switch.

1 Check the cable harness between the air pressure switch and EMS2.

2 Check the switch.

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30-2 Fault Tracing






CIU: Flash code

Symptom:




Flash code


Value fault: 5.6

None.


• Open circuit in the air pressure switch signal cable.

• Short circuit between the air pressure switch signal cable and battery negative.

• Short circuit between the switch supply cable and the switch negative cable.

• Faulty monitor.

1 Check the cable harness between the air pressure switch and EMS2.


3 Check the switch.

A

15

29

SB

OR

EMS2

B

18

SB

31

BL / GN

P0013493 a Connector A b Connector B c Air filter pressure and temperature

C

P2 1

3 4


Air filter pressure and air filter temperature are measured by a combined switch/sensor placed above the air filter. The air filter pressure switch measures absolute pressure, the sum of air filter pressure and atmospheric pressure. The switch activates when the air pressure in the air filter becomes too low (the vacuum between the air filter and the turbo is too high). The engine control unit measures the voltage drop over the pressure switch to detect when the switch has been activated.

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P0013492

30-2 Fault Tracing


Supply voltage: max 24 VDC.

Switching point: -5kPa ±500Pa, -50±5 mbar

Measurements

Checking supply cable, air filter pressure switch page 139

Checking negative cable, air filter pressure switch page 153

Checking air pressure switch page 140

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30-2 Fault Tracing

MID 128, PID 108 Barometric pressure

FMI 2 – Data erratic, intermittent, or incorrect



Plausibility

DCU: None.

CIU: None.



Flash code

Electrical fault: None.

Value fault: None.

Internal fault in the engine control unit.

1 Replace the engine control unit (EMS 2).





DCU: None.

CIU: None.

Symptom:



Flash code


Value fault: None.

Ambient pressure is set to 1.0 bar.







DCU: None.

CIU: None.

Symptom:



Flash code


Value fault: None.

Ambient pressure is set to 1.0 bar.




Sensor is placed inside the engine control unit.

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MID 128, PID 110 Engine coolant temperature




Coolant temperature too high.


CIU: Flash code

Symptom:




Flash code


Value fault: 6.1


Coolant water temperature exceeds the set value of the engine protection parameter.

• Coolant level too low.

• Dust or dirt on the outside of the radiator.

• Drive belt is not properly adjusted.

• Worn impeller in the coolant pump.

• There is air in the coolant water system.

• Faulty thermostat.

• Faulty temperature sensor.

• Clogged cooling water system.

1 Check the coolant level.

2 Check the outside of radiator for dust and dirt.

3 Check the drive belt adjustment.

4 Check the impeller in the coolant pump.

5 Bleed the coolant water system.

6 If low coolant level check the coolant water system for leakage by a pressure test.

7 Check the pressure valve in the coolant cup.

8 Check the coolant water thermostat or change the coolant water thermostat.

9 Check the coolant temperature sensor.

10 Clean the coolant water system.

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30-2 Fault Tracing






CIU: Flash code




Flash code


Value fault: 6.1


• Short circuit between both cables to the coolant temperature sensor.

• Faulty sensor.

1 Check the cable harness between coolant temperature sensor and

EMS2.

2 Check the sensor.






CIU: Flash code




Flash code


Value fault: 6.1


• Open circuit in signal cable to temperature sensor.

• Open circuit in negative cable to temperature sensor.

• Faulty sensor.

1 Check the cable harness between coolant temperature sensor and

EMS2.


B.

3 Check the sensor.

p0004941

TAD950–952VE

TWD1643GE

72

TAD1250–1252VE

47701632 10-2010

b

P0007217 a Coolant temperature b Connector B

a

30-2 Fault Tracing


The coolant temperature sensor consists of a thermistor which forms a closed circuit with an internal resistor in the engine control unit (EMS2). The thermistor resistor changes in a non-linear manner, depending on the coolant temperature. The EMS2 provides the circuit with a reference voltage of +5 Volt. The EMS2 measures the voltage drop over the thermistor via pin 27 and pin 18 on the EMS2. Pin 1 on the sensor is connected to battery negative via pin 18 on the EMS2. When the coolant is cold, the thermistor resistance is high and the EMS2 senses a high voltage drop. As the coolant warms up, the resistance in the thermistor falls and the voltage drop across it falls.


Measurements

Checking signal cable, coolant temperature switch page 155

Checking negative cable, coolant temperature switch page 156

Checking coolant temperature sensor page 141


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74

30-2 Fault Tracing

MID 128, PID 111 Coolant level




Coolant level is too low.


CIU: Flash code

Symptom:


Flash code


Value fault: 2.2


1 Check the coolant level.

2 Bleed the coolant water system.

3 If low coolant level check the coolant water system for leakage by a pressure test.

4 Check the pressure valve in the coolant cup.

5 Check the wiring to the coolant level switch.

6 Check the coolant level switch.

FMI 3– Voltage above normal or shorted high



Faulty switch / Faulty switch circuit


CIU: Flash code




Flash code


Value fault: 2.2

The voltage on pin B23 in the engine control unit is too high.

Short circuit to battery voltage on pin B23.

1 Check the cable harness between the coolant level switch and the

EMS2.

47701632 10-2010

A

10

SB

23

EMS2

P0013497

LBN

a Connector B b Coolant level

B

2

1

30-2 Fault Tracing


The coolant level in the engine is monitored by a level switch. Pin 23 on the engine control unit (EMS2) provides pin 1 on the level switch with supply voltage. Pin

2 on the level switch is connected to battery negative via pin 10 on the engine control unit. The level switch has two states: On/Off.

The level switch consists of two sections, the actual switch and a magnetic float which is built into the expansion tank. The switch senses the position of the magnetic float. When the coolant level falls, the float operates the switch and a closed circuit is formed.

Measurements

Checking supply cable, coolant level switch page 143

Checking negative cable, coolant level switch page 143

Checking coolant level switch page 144

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30-2 Fault Tracing

MID 128, PID 153 Crankcase pressure




Crankcase pressure is rising too fast.


CIU: Flash code

Symptom:




Flash code


Value fault: 7.7

The engine is shut down if the engine protection parameter is activated.

Crankcase pressure rises too fast.

• Blocked crankcase ventilation.

• Faulty crankcase pressure sensor.

• Worn or damaged cylinder liners, piston or piston rings.

1 Check whether the crankcase ventilation is blocked. Clean the crankcase ventilation system.

2 Check all cable and connectors between the EMS2 and the crankcase pressure sensor.

3 Check the crankcase pressure sensor.

4 Control measure the crankcase pressure.

5 Check whether cylinder liner, piston or piston rings are worn or damaged.






CIU: Flash code




Flash code


Value fault: 7.7

The voltage on pin B28 in the engine control unit exceeds 4.78 Volt.

• Short circuit between sensor signal cable and 5V supply or battery voltage to crankcase pressure sensor.

• Open circuit in the sensor negative cable.

• Faulty sensor.

1 Check the cable harness between the crankcase pressure sensor and the EMS2.


3 Check the sensor.

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CIU: Flash code




Flash code


Value fault: 7.7

The voltage on pin B28 in the engine control unit is less than 0.30 Volt.

• Open circuit in the sensor 5 Volt supply.

• Open circuit in the sensor signal cable.


• Faulty sensor.

1 Check the cable harness between the crankcase pressure sensor and the EMS2.


B.

3 Check the sensor.

b

P0007226 a Crankcase pressure b Connector B

a


The sensor which measures the crankcase pressure is an active sensor, i.e. it must have operating voltage.

The engine control unit, connector B, pin 17, supplies the sensor, pin 1 with +5 Volt. The sensor, pin 4, is connected to battery negative via the engine control unit, connector B, pin 18.

The output signal from the pressure sensor, pin 2, to the engine control unit, connector B, pin 28, is a voltage signal which is proportional to the crankcase pressure.

It is the velocity of a rising crankcase sure that trigger the alarm. The output signal is linear within the sensors working range.

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30-2 Fault Tracing


Working range: 0.4 – 1.4 bar = 40 – 140 kPa

Supply voltage: 5.00 +/- 0.25 VDC


5.00 VDC:

0.5 VDC @ 0.4 bar = 40 kPa

4.5 VDC @ 1.4 bar = 140 kPa

Measurements

Checking negative cable, crankcase pressure sensor page 174

Checking signal cable, crankcase pressure sensor page 174

Checking supply cable, crankcase pressure sensor page 175

Checking crankcase pressure sensor page 144

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MID 128, PID 158 ECU battery potential




Battery voltage too low.


CIU: Flash code

Symptom:




Flash code

Electrical fault: None (EMS)

Value fault: None (EMS)

Electrical fault: None (CIU)

Value fault: None (CIU)

Could be engine starting problems.

Battery voltage less than 25.5 V engine running.

• Altenator belt

• Flat / poor batteries

• Fault in cables or connectors for battery / altenator

• Faulty altenator

1 Check battery cables.

2 Check / charge batteries.

3 Check altenator and drive belt.

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MID 128, PID 172 Inlet air temperature






CIU: Flash code

Symptom:




Flash code


Value fault: None.

None.


• Short circuit between both cables to the air filter temperature sensor.

• Faulty sensor.

1 Check the cable harness between air filter temperature sensor and

EMS2.

2 Check the sensor.






CIU: Flash code

Symptom:




Flash code


Value fault: None.

None.


• Open circuit in signal cable to the air filter temperature

• Open circuit in negative cable to the air filter temperature sensor.

• Faulty sensor.

1 Check the cable harness between air filter temperature sensor and

EMS2.


B.

3 Check the sensor.

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P0013492

A

15

29

SB

OR

EMS2

B

18

SB

31

BL / GN

P0013493 a Connector A b Connector B c Air filter pressure and temperature

C

P2 1

3 4

30-2 Fault Tracing


The air filter temperature sensor consists of a thermistor which forms a closed circuit with an internal resistor in the engine control unit (EMS2). The thermistor resistor changes in a non-linear manner, depending on the air temperature. The EMS2 provides the circuit with a reference voltage of +5 Volt. The EMS2 measures the voltage drop over the thermistor via pin 18 and pin 31 on the EMS2. Pin 3 on the sensor is connected to battery negative via pin 18 on the EMS2. When the air into the filter is cold, the thermistor resistance is high and the EMS2 senses a high voltage drop. As the air into the filter warms up, the resistance in the thermistor falls and the voltage drop across it falls.


Measurements

Checking signal cable, air filter temperature switch page 145

Checking negative cable, air filter temperature switch page 146


Checking air inlet temperature sensor page 148

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MID 128, PID 173 Exhaust gas temperature




Symptom:



Exhaust gas temperature is too high.

A red lamp flashes in the alarm panel + audible warning.

Engine is derated.

Exhaust temperature exceeds the set value of the engine protection parameter. (For parameters, see the engine protection map.)

1 Check that the exhaust pipe has not been damaged and that there are no restrictions.

2 Check the sensor.

3 Check the exhaust back pressure.




Symptom:




None.

None.

The voltage on pin B44 in the engine control unit is less than 0.07 Volt.

• Short circuit between the sensor signal cable and the sensor negative cable.


• Faulty sensor.


2 Check the sensor.




Symptom:




None.

None.

The voltage on pin B44 in the engine control unit exceeds 4.95 Volt.

• Open circuit in the sensor signal cable.


• Open circuit in the sensor negative cable.

• Faulty sensor.



B.

3 Check the sensor.

82 47701632 10-2010

P0013504

A

(-)18

SB

VO

(+)44

EMS2

P0013505

A Connector B

B Exhaust temperature sensor

B

2

1

30-2 Fault Tracing


Exhaust temperature sensor consists of a Pt-200 sensor where the resistance changes depending on exhaust temperature. The resistance increases with rising exhaust temperature.

Pin 44 on the engine control unit (EMS2) connector B provides pin 2 on the sensor with an operating voltage of +5 Volt. Pin 1 on the sensor is connected to battery negative via pin 18 on the EMS2. The voltage drop across the sensor changes as exhaust temperature changes.

Measurements

Checking signal cable, exhaust gas temperature sensor page 148

Checking negative cable, exhaust gas temperature sensor page 149

Checking exhaust gas temperature sensor page 149

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MID 128, PID 175 Engine oil temperature




Engine oil temperature too high.


CIU: Flash code

Symptom:



Flash code


Value fault: 5.8


Engine oil temperature is too high.

1 Check the oil level in the engine.

2 Check the coolant level and the engine temperature.

3 Check that no leakage occurs.

4 Check the sensor.

5 Clean the oil cooler system and check the bypass valve for the oil cooler.

Please refer to more detailed instructions in the “Workshop manual group 22,

Lubrication system”.






CIU: Flash code




Flash code


Value fault: 5.8

The voltage on pin A31 in the engine control unit is less than 0.07 Volt.

• Short circuit between the oil temperature signal cable to the sensor negative cable.

• Short circuit between the oil temperature signal cable and the sensor

5V supply cable.

• Short circuit between oil temperature signal cable and oil level signal cable.

• Fault in sensor.


2 Check the sensor.

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30-2 Fault Tracing






CIU: Flash code




Flash code


Value fault: 5.8

The voltage on pin A31 in the engine control unit exceeds 4,95 Volt.

• Open circuit in the oil temperature signal cable.

• Open circuit in the oil temperature negative cable.



2 Check the contact pressure in socket 31 in the engine connector A and in socket 10 in engine connector B.

3 Check the sensor.

b

3

10

GN/SB

SB

4

GN/W

4 1

2 3 c


The oil temperature and the oil level sensor is a combined sensor. The oil temperature sensor consists of a thermistor which forms a closed circuit with an internal resistor in the engine control unit (EMS2). The thermistor resistor changes in a non-linear manner, depending on the oil temperature. The EMS2 provides the circuit with a reference voltage of +5 Volt via pin 31 in connector A. The EMS2 measures the voltage drop over the thermistor via pin 18 and pin 31 on the EMS2.

Pin 4 on the sensor is connected to battery negative via pin 18 in connector B on the EMS2. When the oil is cold, the thermistor resistance is high and the EMS2 senses a high voltage drop. As the oil warms up, the resistance in the thermistor falls and the voltage drop across it falls.


a

P0008588

EMS2

31

GR/OR a Connector A b Connector B c Oil temperature and level

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Measurements

Checking negative cable, oil temperature switch page 150

Checking signal cable, oil temperature switch page 151

Checking oil temperature sensor page 152

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MID 128, PID 190 Engine speed




Engine is / was overspeeding


CIU: Flash code

Symptom:



Flash code


Value fault: 2.6

Engine speed limited.

Too high engine speed.

1 After the engine has stopped search for the reason for the high speed.

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MID 128, PPID 3 Starter Output




Starter output failure.

EMS: Flashcode

Symptom:

Preconditions:



Flash code


Value fault: None.

The engine cannot be started.

The engine starts immediately when ignition is turned on.

General check for starter motor problems

• Check the starter motor cables and the connections.

• Check that the starter relay pull during the start attempt.

• Short circuited ignition cable to 5V voltage or to battery voltage.

• Ignition signal activated too long.

• Faulty start button/key switch.

1 Check that the key switch is connected correctly.

2 Check cable harness between EMS2 and the CIU key switch.

3 Check the function of the key switch.

4 Faulty start button on the DCU.




Starter output failure.

EMS: Flashcode

Symptom:

Preconditions:




Flash code


Value fault: None.






The voltage on pin B29 in the engine control unit is less than normal voltage.

• Short circuited ignition cable to battery negative.

• Faulty key switch.

1 Check the ignition cable.




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30-2 Fault Tracing




EMS: Flashcode

Symptom:

Preconditions:




Flash code


Value fault: None.






The voltage on pin B29 in the engine control unit is less than normal voltage.

• Open circuit in ignition cable.

• Faulty start relay.

1 Check the ignition cable.

2 Check the start relay on the starter motor.

3 Check the prestart relay. (only on TAD1250-1252VE)



The engine control unit pin B29 senses when ignition is switched on that the start relay coil is intact. When ignition on there is battery voltage potential on pin B29.

When the starter is activated the voltage potential on pin B29 drops to 0V. On the TAD950-952VE and on the TAD1350-1355GE engines there is one starter relay on the startermotor. The TAD1250-1252VE engine also has a prestart relay.

Measurements

Checking starter motor relay page 153

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30-2 Fault Tracing

MID 128 / 144, PPID 4 Starter input sensor




Starter input failure.

CIU: Flashcode

Symptom:



Flash code

Electrical fault: 4.7 (EMS)


Electrical fault: 5.2 (CIU)




• Ignition signal activated too long.

• Faulty key swich.







Starter input failure.

CIU: Flashcode

Symptom:



Flash code







• Short circuited ignition cable to battery negative.

• Faulty key swich.




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30-2 Fault Tracing

MID 128, PPID 6 Key off input sensor




Faulty circuit.


CIU: Flash code

Symptom:




Flash code





Engine can only be stopped using the auxiliary stop.

Engine can only be stopped using the auxiliary stop.

Short circuit between the engine stop signal in engine connector and battery negative.

1 Check the stop signal cable between the engine control unit A27 and the CIU/DCU.


The stop input signal to the engine control unit pin A27 can have one of two signal levels, high/low. The A27 stop input on the EMS2 can be set via a parameter in

Vodia to work in one of two ways.

Either the EMS2 stop input is set to “energized to run” which means that the stop input signal to the EMS2 pin

A27 must be high in order for the engine to be able to run or the EMS2 stop input is set to “energized to stop” which means that the stop input signal on the EMS2 pin A27 must be high in order for the engine to stop.

In the first case the stop input signal level has to be low to shut down the engine.

In the second case the stop input signal level has to be high to shut down the engine.

Measurements

Checking stop signal cable between ECU and CIU/

DCU page 154

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MID 128, PPID 8 Piston Cooling Oil

Pressure




Piston cooling oil pressure is too low.


CIU: Flash code

Symptom:



Flash code


Value fault: 6.7

Engine is derated. The fault code is deactivated at engine speed below 1000 rpm.

Piston cooling pressure is too low.

1 Re-check the piston cooling pressure. If measurement shows that the piston cooling pressure is correct, change the piston cooling pressure switch.






CIU: Flash code




Flash code


Value fault: 6.7

The voltage on pin B14 in the engine control unit exceeds normal voltage value.

Short circuited piston cooling signal cable to battery voltage.

1 Check cable harness between EMS2 and the piston cooling switch.

92 47701632 10-2010

A

10

SB

14

GR / R

EMS2

P0013511

A Connector B

B Piston cooling pressure

SB

B

2

P

1

30-2 Fault Tracing


A valve is installed in the oil filter bracket which opens or closes the oil supply for piston cooling, depending on oil pressure. If the oil pressure is below 250 kPa

(TAD950-952VE) or 300 kPa (TAD1250-1252VE), the valve closes the oil supply for piston cooling.

The piston cooling pressure is monitored by a pressure switch. The output signal from the pressure switch, pin

1 to the engine control unit, can only have two distinct positions, on/off. The switch is supplied with current from the engine control unit pin 10. A pre-set pressure limit of 150 kPa determines when it switches on. The switch opens if the pressure exceeds this value.

At idle, the switch can be closed without a fault code being set.


Switching point: 150kPa = 1.5bar

Supply voltage: 12-24 VDC

Measurements

Checking negative cable, piston cooling oil temperature switch page 156

Checking supply cable, piston cooling oil temperature switch page 157

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MID 128, PPID 19 Internal EGR

Status






CIU: Flash code

Symptom:




Flash code


Value fault: None.

IEGR can not be turned on. If the IEGR function would fail (not being activated) the result will be an increased exhaust production with high NOX and possible over speeding of the turbocharger.

The voltage on pin B30 on the EMS2 deviates from normal voltage value.

Short circuited IEGR signal cable to 5V voltage or to battery voltage.

1 Check cable harness between EMS2 and the IEGR.






CIU: Flash code

Symptom:




Flash code


Value fault: None.



Short circuited IEGR signal cable to battery negative.


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30-2 Fault Tracing






CIU: Flash code

Symptom:



Flash code


Value fault: None.


Open circuit in one or both of the cables to the IEGR.


2 Check the contact pressure in socket 30, 57 and 60 in the engine connector B.

3 Check the IEGR coil.

FMI 7 – Mechanical system not responding properly



Mechanical fault.


CIU: Flash code

Symptom:



Flash code


Value fault: None.


• IEGR solenoid mechanically stucked.

• Too low oil pressure to activate the IEGR.

1 Check the function of the IEGR solenoid.

2 Check the engine oil pressure.

P0013515

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30-2 Fault Tracing

A

30

(+) 57

(+) 60

EMS2

P0013516 a Connector B b IEGR

GN

R /BL

1

B

2


Internal exhaust gas recirculation, IEGR, is like the name says used for recirculation of exhaust gases.

This for lowering the emissions from the engine. The

IEGR control valve, is located on the cylinder head under the valve cover. It is used to regulate the oil pressure to the rocker arm shaft and from there to the

IEGR double rocker. The IEGR valve is a 2-way solenoid valve controlled by the engine control unit. When the IEGR not activated an oil pressure on one side of the solenoid and the solenoid spring force on the other side of the solenoid keeps the solenoid in balance.

When the IEGR function is activated the solenoid changes position and the oil pressure to the rocker arm shaft increases. The solenoid is activated when pin 30 in connector B changes its potential.

Measurements

Checking IEGR wiring page 163

Checking the IEGR coil page 157

Checking IEGR solenoid page 158

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30-2 Fault Tracing

MID 128, PPID 55 ECU temperature




ECU temperature is too high.


CIU: Flash code

Symptom:




Flash code


Value fault: None.

None.

The temperature inside the engine control unit is too high.

• High surrounding temperature.


1 Check if the surrounding temperature is high or if the EMS 2 unit is exposed to heat radiation.

2 Change EMS 2 unit.

FMI 4 – Voltage below normal or short circuit to lower voltage





CIU: Flash code

Symptom:



Flash code


Value fault: None.

None.

Fault in sensor circuit.







CIU: Flash code

Symptom:



Flash code


Value fault: None.

None.

Fault in sensor circuit.


47701632 10-2010


The temperature sensor is installed inside of the EMS

2 unit.

97

30-2 Fault Tracing

MID 128, PPID 98 Engine sync acknowledge

FMI 9 – Abnormal update rate



Communication fault.


CIU: Flash code

Preconditions:




Flash code


Value fault: None.

NOTICE! If the control panel ONLY communicates on the J1939 communication and NOT the redundancy of J1587 for start, stop and throttle this fault code is active in the VODIA and that is normal.

“Time-out” on the J1587 bus.

• Fault in the communication with the DCU/CIU.

• No DCU/CIU found.

• Open circuit in the power supply cable between the engine control unit and the DCU/CIU.

• Faulty DCU/CIU.

1 Check the communication cables to the DCU/CIU.

2 Check the power supply cable between the engine control unit and the

DCU/CIU.

3 Check that the DCU/CIU is programmed for the correct engine type.

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30-2 Fault Tracing

MID 128 / 144, PPID 132 Throttle calibrated position




Faulty throttle potentiometer / Faulty throttle potentiometer circuit


CIU: Flash code

Symptom:

Preconditions:



Flash code


Value fault: None.

Engine goes to idle. If the accelerator is released at first and then pressed down again the engine can be forced to run using the idle contact.


• Open circuit in any or all of the throttle signals.

• Short circuited throttle potentiometer signal cable to 5V voltage or to battery voltage.

• Faulty sensor.

1 Check that the throttle potentiometer is connected correctly.

2 Check cable harness between CIU and the CIU throttle potentiometer.

3 Check the function of the throttle potentiometer. Check the contact pressure in socket 2, 3 and 3 in the CIU connector.




Faulty throttle potentiometer / Faulty throttle potentiometer circuit


CIU: Flash code

Symptom:

Preconditions:



Flash code


Value fault: None.



• Short circuited throttle potentiometer signal cable to battery negative.

• Faulty sensor.



3 Check the function of the throttle potentiometer.

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FMI 9 – Abnormal update rate



EMS2 is missing the throttle signal.


CIU: Flash code

Symptom:

Preconditions:



Flash code


Value fault: None.



EMS2 recieves no throttle signal on the J1939 bus from the CIU.



3 Check the function of the throttle potentiometer.


GN / SB (-)

GN / Y

(+)

GN / OR

A

1 2 3

3

CIU

P0013518

2 30

A Throttle pot.

Measurements

Vodia logging throttle signal page 175

100 47701632 10-2010

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MID 128, PPID 332 Thermostat




Faulty sensor / Faulty circuit


CIU: None.




Flash code


Value fault: None.


• Short circuited coldstart valve signal cable to 5V voltage or to battery voltage.

• Faulty coldstart valve.

1 Check all cable and connectors between EMS2 and coldstart valve.

2 Check coldstart valve.






CIU: None.




Flash code


Value fault: None.


• Short circuited coldstart valve signal cable to battery negative or to lower voltage.









CIU: None.




Flash code


Value fault: None.


• Open circuit in coldstart valve signal cable.

• Open circuit in coldstart valve battery voltage cable.



2 Check contact pressure in socket 34 engine connector B.


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30-2 Fault Tracing

P0013519

34

(+)57,60

VO

R /BL

A

EMS2

P0013520

A Junction point

B Cold start valve

1

B

4


In order to avoid boiling in the charge air coolers at different loads and coolant temperatures, the system is fitted with a cold start valve that is controlled by the

EMS2. The cold start valve is normally open i.e. without voltage supply the valve is open. The cold start valve is supplied with battery voltage at pin 4. Pin 1 is connected to pin B34 at the EMS2. When the cold start valve is activated(valve closes) pin B34 alter its voltage potential from battery voltage to approx. 0.2 Volt.

If the intake manifold temperature signal or the coolant temperature signal is lost the cold start valve opens.

Under normal conditions, the cold start valve is opened at: intake manifold temperature>50° AND coolant water temperature<86°.

Under normal conditions, the cold start valve is closed at: intake manifold temperature<45° OR coolant water temperature>92°.

Measurements

Checking supply cable, coldstart valve page 159

Checking negative cable, coldstart valve page 160

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MID 128, SID 1/2/3/4/5/6 Injector # 1-6


(Short to battery voltage, injector low voltag side)


Fault in the injection system.



CIU: Flash code

Symptom:

Preconditions:




Flash code

Electrical fault: 7.1–7.6

Value fault: None.

Faulty unit injector is shut off, engine runs on 5 cylinders. Limp home on rest of unit injectors. Engine performance is reduced. Abnormal sound.

NOTICE! Identify which injector by the SID number.

Injector activated and faulty voltage in injector low side.

• Short circuit to battery voltage on the pin on the respective injector’s low voltage side. (EMS2 pin: 36, 40, 44, 48, 52, 56 and 12, 16, 20, 24,

28, 32)

• Short circuit between high voltage and low voltage sides.

• Short circuit to battery voltage in low voltage injector wire.

1 Check the cable harness between injectors and engine control unit

(EMS2).


(Short to battery negative, injector high voltage side)





CIU: Flash code

Symptom:

Preconditions:




Flash code


Value fault: None.



Injector activated and faulty voltage in injector high side.

• Short circuit to battery negative on the pin on the respective injector’s high voltage side. (EMS2 pin: 59, 60, 61 and 62)

• Short circuit to battery negative in high voltage injector wire.


(EMS2).

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30-2 Fault Tracing


(Break in injector circuit.)





CIU: Flash code

Symptom:

Preconditions:




Flash code


Value fault: None.



Injector activated and faulty voltage in injector high or low side.

• Open circuit in low voltage wiring side or high voltage wiring side.

If three injection fault codes are set there is an Open circuit on the high side. If one injection fault code is set there is an Open circuit on the low side.

• Short circuit to battery voltage on the pin on the respective injector’s high voltage side. (EMS2 pin: 59, 60, 61 and 62)

• Short circuit to battery negative on the pin on the respective injector’s low voltage side. (EMS2 pin: 36, 40, 44, 48, 52, 56 and 12, 16, 20, 24,

28, 32)


(EMS2).

2 Check the contact pressure in all sockets regarding the unit injectors in engine connector A.

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30-2 Fault Tracing






CIU: Flash code

Symptom:

Preconditions:




Flash code


Value fault: None.



Injector activated and cylinder balancing above limit.

If a fault code is set when the engine has an unsymmetrical load it can not be rectified. At idle speed the engine control unit is trying to compensate for uneven running by adding more or less fuel to the injectors, cylinder balancing. If the engine load is too unsymmetrical the compensation is not enough and a fault code will be set.

• Unsymmetrical load of the engine.

• Poor / uneven compression.

• Faulty injector.

1 Clear the fault code with the Vodia tool. Let the engine run at idle speed without any load and see if the faultcode reappear.

2 Perform test of cylinder compression using the VODIA tool.

3 Change only the faulty injector.

FMI 12 – Faulty device or component

(Low unit injector hold current)





CIU: Flash code

Symptom:

Preconditions:




Flash code


Value fault: None.



Low injector hold current. Injector activated.

Intermittent fault.

1 Check the cables between the injector and the engine control unit.

2 Check the contact pressure in all sockets regarding the unit injectors in engine connector A.

3 Check the cable connection to the injector.

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a b

4

5

6

1

2

3

P0008674 a Connector A b Cylinder


The Delphi E3 electronic unit injectors used on the tier3 engines have two electronically controlled solenoids.

Each solenoid is individual controlled by the engine control unit.

The unit injectors receive voltage from pin 59, 60, 61 or 62 on the engine control unit. To activate a unit injector solenoid the engine control unit connects the unit injectors low side to battery negative.

Measurements

Trimming the injector page 161

Checking the injector wiring page 162

P0013523

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MID 128, SID 21 Engine position






CIU: Flash code

Symptom:




Flash code


Value fault: None.

The engine start time will increase, uses only crankshaft sensor.

Incorrect timing.

• Polarity fault. The cables to the cam speed sensor is shifted.

• Intermittent fault.

• Incorrectly mounted cam speed sensor.

1 Check the cable harness between the cam speed sensor and EMS2.

2 Check that the cam speed sensor is connected as in the circuit description.

3 Check the cam speed sensor.


(No signal)





CIU: Flash code

Symptom:




Flash code


Value fault: None.


No camsignal when expected.


• Open circuit in any or both of the cables to the crank speed sensor.

• Short circuit between the cables to the cam speed sensor.

• Faulty cam speed sensor.

1 Check the installation of the cam speed sensor.

2 Check the cable harness between the cam speed sensor and EMS2.

3 Check the cam speed sensor.


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FMI 8 – Abnormal frequency, pulse width, or period





CIU: Flash code

Symptom:




Flash code


Value fault: None.


Incorrect sensor signal.


• Electrical interference in the cam speed signal.

1 Check wiring between cam spped sensor and EMS2.

2 Check the installation of the cam speed sensor.

3 Attempt to localize the source of interference.

4 Check and clean the cam speed sensor.


a Connector A b Engine speed sensor, camshaft


The camshaft sensor is an inductive sensor. The camshaft sensor is used in the first instance to determine the cylinder which is next in line for injection. A toothed wheel installed on the camshaft is used to determine the cylinder which is next in line for injection. The toothed wheel has 7 teeth, one for each cylinder plus an extra tooth for cylinder 1. When the camshaft with toothed wheel rotates, impulses are generated in the sensor. The impulses generated by in the sensor is used by the engine control unit to determine the cylinder which is next in line for injection.

Measurements

Checking camshaft sensor wiring page 164

Checking camshaft sensor page 165

P0008694

TAD950–952VE

TAD1350–1352GE TAD1250–1252VE

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30-2 Fault Tracing

MID 128, SID 22 Timing sensor, crank






CIU: Flash code

Symptom:




Flash code


Value fault: None.

Engine is difficult to start, uses only cam sensor.

Incorrect signal.

• Short circuit between the cables to the flywheel sensor.

• Polarity fault. The cables to the flywheel sensor is shifted.

1 Check the cable harness between the flywheel sensor and EMS2.

2 Check that the flywheel sensor is connected as in the circuit description.

3 Check the flywheel sensor.


(No signal)





CIU: Flash code

Symptom:




Flash code


Value fault: None.

Engine is running with imprecise timing causing risk of high fuel consumption and smoke. Cylinder balancing not working with risk of uneven running.

No cranksignal when expected or permanent loss of sensor signal.

• Open circuit in any or both of the cables to the flywheel sensor.

• Incorrectly mounted flywheel sensor.

• Faulty flywheel sensor.

1 Check the cable harness between the flywheel sensor and EMS2.

2 Check the installation of the flywheel sensor.

3 Check the flywheel sensor.


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CIU: Flash code

Symptom:




Flash code


Value fault: None.

Engine is difficult to start, uses only cam sensor.

Incorrect flywheel sensor signal.

• Incorrectly mounted flywheel sensor.

• Electrical interference in the flywheel signal.

1 Check wiring between flywheel sensor and EMS2.

2 Check the installation of the flywheel sensor.

3 Attempt to localize the source of interference.

4 Check and clean the flywheel sensor.


a Connector A b Engine speed sensor, crankshaft


The flywheel sensor is an inductive sensor. The flywheel sensor is used to monitor engine speed. It is also used to measure the cylinder acceleration. The flywheel has three times eighteen depressions for one rotation. These depressions are detected by the flywheel sensor and generate a pulsed signal which the engine control unit uses to detect flywheel rotation speed. Two cylinders share one sector of the depressions (cylinders 1 and 6, 2 and 5, 3 and 4) on the flywheel. This means that it is not possible to know which cylinder.

Measurements

Checking flywheel sensor wiring page 166

Checking flywheel sensor page 167

P0008694

TAD950-952VE

TAD1350-1352GE

TWD 1643GE TAD1250-1252VE

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MID 128, SID 32, Wastegate output driver




Faulty regulator / Faulty regulator circuit


CIU: None.




Flash code


Value fault: None.


• Short circuited wastegate regulator signal cable to 5V voltage or to battery voltage.

• Faulty wastegate regulator.

1 Check all cable and connectors between EMS2 and wastegate regulator.

2 Change wastegate regulator.






CIU: None.




Flash code


Value fault: None.


• Open circuit in wastegate battery voltage supply cable.

• Short circuited wastegate regulator signal cable to battery negative or to lower voltage.




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CIU: None.




Flash code


Value fault: None.


• Open circuit in wastegate regulator signal cable.

• Open circuit in wastegate regulator battery negative cable.



2 Check contact pressure in socket 38 engine connector B.


TAD1350-52 GE

P0013528

TWD1643 GE

112 47701632 10-2010

38

(+)57,60

(-)58,59

GN

R / BL

SB

A

EMS2

P0013529

B

(TWD1643 GE)

2

1

7

C

A Connector B

B Junction points

b

C Wastegate

TWD1643 GE

a

2

1

(+) 57

R / BL

(+) 60

R / BL

38

EMS

P0007253

GN

a Wastegate b Connector B

TAD1350-52 GE

30-2 Fault Tracing


The engine is equipped with a turbocharger with a wastegate valve. The wastegate valve controls the amount of exhaust gas flow which should pass through the exhaust turbine. An electronically controlled regulation valve, wastegate regulator, which is controlled by the engine control unit controls the air pressure supplied to the wastegate valve. Air pressure taken from the inlet manifold is used to control the amount that the wastegate opens. As the air pressure supplied by the control valve to the wastegate valve increases, the valve opens wider. When the wastegate valve is fully open, the exhaust gas flow to the exhaust turbine is at its lowest.

The control valve is current controlled by the engine control valve, using a PWM signal. As the current supplied to the control valve increases, the boost air pressure increases. The boost air pressure is constantly monitored by a sensor installed in the inlet manifold.

Measurements

Checking negative cable, wastegate valve page 168

Checking supply cable, wastegate valve page 169

Checking the wastegate valve page 170

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MID 128, SID 70 Air inlet heater driver #1




Faulty relay / Faulty relay circuit


CIU: None.

Symptom:



Flash code


Value fault: None.

Fuse for shorting wire breaks.

• Short circuit to battery voltage in sense wire.

• Heating element broken.

1 Check all cable and connections to heating element.

2 Check function of preheat relay.

3 Check heating element.






CIU: None.

Symptom:



Flash code


Value fault: None.

Start problems in cold climate.

Short circuit to battery negative in sense wire.

1 Check function of preheat relay.


114 47701632 10-2010

30-2 Fault Tracing






CIU: None.

Symptom:



Flash code


Value fault: None.

Might get start problems in cold climate.

• Preheater fuse broken.

• An open circuit in sense wiring.

• Heating element broken.

1 Check preheater fuse.

2 Check contact pressure in socket 7 in engine connector B.


4 Check heating element.

34

(+)57,60

7

OR

R / BL

BN

A

EMS2

P0013533

B

C


In cold climate the intake air might need too be preheated. This is done by the preheater located on the intake manifold. A sense wire is connected between the preheater relay output and B7. The sense wire checks that the preheat element and the preheat fuse are not damaged. The activation of the preheater is controlled by the EMS2 via the preheat relay. EMS2 pin B25 activates the preheat relay.

A Connector B

B Junction point

C Preheat relay

Preheater fuse is located between preheat relay and heating element.

P0013532

Measurements

Checking preheater relay page 171

47701632 10-2010 115

30-2 Fault Tracing

MID 128, SID 211 Sensor Supply

Voltage #2 (+5V DC)




Fault in circuit.


CIU: Flash code

Symptom:




Flash code


Value fault: None.

None.

Abnormally high voltage or short circuit to higher voltage on pin B17.

Short circuit to battery voltage.

1 Check the supply voltage to the sensors which have set fault codes.

2 Check sensor cables.

3 Check the sensors.




Fault in circuit.


CIU: Flash code

Symptom:




Flash code


Value fault: None.

None.

Abnormally low voltage or short circuit to battery negative has on pin B17.

• Short circuit sensor supply voltage cable to battery negative, fuel pressure sensor.

• Short circuit sensor supply voltage cable to battery negative, crankcase sensor.

1 Check the supply voltage to the above-mentioned sensors.




Pin B17 on the EMS2 distributes 5 Volt supply voltage to the crankcase pressure sensor and the fuel pressure sensor.

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30-2 Fault Tracing

MID 128 / 144, SID 231 SAE J1939 data link




Communication fault J 1939


CIU: Flash code

Symptom:




Flash code





Engine can not be started or if engine is running it can only be stopped by pushing the aux-stop.

Instruments and warning lamps stop working.

CAN communication is missing.

• CAN H and CAN L short circuited to eachother.

• CAN H or CAN L short circuited to battery negative on pin 3.

• CAN L short circuited to power supply on pin 4.

• CAN H or CAN L short circuited to any of the J1708 links.

1 Check all data links between DCU/CIU and EMS2.


B.

3 Check that the socket 11 and 12 in the CIU connector is undamaged.

A

B

C

D

E

F

G

H

EMS2

P0013534 a Engine connector a

Y/W 1

GR/Y 2

SB 3

R 4

R/BL 5

GR/SB 6

W 7

W/SB 8

DCU/CIU


A CAN H – Engine connector

B CAN L – Engine connector

C Power supply, 0 V

D Power supply, input

E Ignition

F Stop

G J1708A – Engine connector

H J1708B – Engine connector

Measurements

Checking CAN bus cable page 171

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30-2 Fault Tracing

MID 128, SID 232 5 V supply




Fault in circuit.


CIU: Flash code

Symptom:




Flash code


Value fault: None.

None.

Abnormally high voltage or short circuit to higher voltage on pin A7.

Short circuit to battery voltage.

1 Check the supply voltage to the sensors which have set fault codes.






Fault in circuit.


CIU: Flash code

Symptom:




Flash code


Value fault: None.

None.

Abnormally low voltage or short circuit to battery negative on pin A7.

• Short circuit sensor supply voltage cable to battery negative, oil pressure sensor.

• Short circuit sensor supply voltage cable to battery negative, air inlet pressure sensor.

1 Check the supply voltage to the above-mentioned sensors.




Pin A7 on the EMS2 distributes 5 Volt supply voltage to the oil pressure sensor and the air inlet pressure sensor.

118 47701632 10-2010

30-2 Fault Tracing

MID 128, SID 240 Program memory



FMI 11 – Unidentifiable error

FMI 14 – Special instructions





CIU: Flash code

Symptom:




Flash code


Value fault: None.

Engine might not start.

Signal value is irregular, intermittent or incorrect. Data communication interrupted.

Memory fault in the EMS2.

1 Reprogram the EMS2.

2 Change the EMS2.

47701632 10-2010 119

30-2 Fault Tracing

MID 128, SID 250 SAE J1708/J1587 data link




Communication fault J1587/J1708


CIU: Flash code

Symptom:



Flash code


Value fault: None.

None.

Faulty data link.

1 Check all data links between DCU/CIU and EMS2.


3 Check that the socket 22 and 37 in the CIU connector is undamaged.

A

B

C

D

E

F

G

H

EMS2

P0013534 a Engine connector a

Y/W 1

GR/Y 2

SB 3

R 4

R/BL 5

GR/SB 6

W 7

W/SB 8

DCU/CIU


A CAN H – Data Link to Engine

B CAN L – Data Link to Engine

C Power supply, 0 V

D Power supply, input

E Ignition

F Stop

G J1708A – Data Link to Engine

H J1708B – Data Link to Engine

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30-2 Fault Tracing

MID 128 / 144, SID 253 Calibration memory EEPROM



FMI 14 – Special instructions





CIU: Flash code

Symptom:



Flash code





Engine does not start.

• Internal fault in control unit.

• Program fault.

1 Reprogram the unit which set the faultcode.

2 Change the unit which set the faultcode.

47701632 10-2010 121

30-2 Fault Tracing

MID 128 / 144, SID 254 Controller 1







CIU: Flash code



Flash code





• If faultcode MID 144, SID 254, FMI 11 appears the CIU throttle positive and negative supply wire could be short circuited to eachother.

• Faulty EEPROM, CIU.

• Faulty flash memory, CIU.

• Fault in control unit, CIU.

1 Check for short circuit in the supply cables to the CIU throttle potentiometer.

2 Reprogram the unit which set the faultcode.

122 47701632 10-2010

30-2 Fault Tracing

MID 128, PSID 201 Data link, MID144

FMI 9– Abnormal update rate



Communication error.


CIU: None.

Symptom:




Flash code


Value fault: None.

None.

No communication with the engine control unit.

• An open circuit in CAN H or CAN L or both CAN links between EMS 2 and DCU/CIU.

• An open circuit in Power supply 0V cable between EMS 2 and DCU/

CIU.

• An open circuit in Power supply input cable between EMS 2 and DCU/

CIU.

• CAN H short circuited to power supply in pin 4.

1 Check contact pressure in socket 51 and 55 in engine connector B.

2 Check for an open circuit or short circuit between cables in the cable harness between the DCU/CIU and EMS 2, via the engine connector.

A

B

C

D

E

F

G

H

EMS2

P0013534 a A27 Engine connector a

Y/W 1

GR/Y 2

SB 3

R 4

R/BL 5

GR/SB 6

W 7

W/SB 8

DCU/CIU


A CAN H – Data Link to Engine

B CAN L – Data Link to Engine

C Power supply negative

D Power supply positive

E Ignition

F Stop

G J1708A – Data Link to Engine

H J1708B – Data Link to Engine

Measurements

Checking the CAN bus cable page 173

47701632 10-2010 123

30-2 Fault Tracing

No fault code

Fuel bleeding pump (only TAD950–952VE)

Symptom:


Fuel bleeding pump doesn’t start when the fuel press switch is activated.

• Open circuit in any of the cables to the pump motor.


• Faulty fuel press switch.

• Faulty pump motor.

1 Check the cables to the pump motor.

2 Check the fuel press switch.

3 Try another pump motor.

Conn. B

(+) 17

(-) 18

16

R

SB

GN / BL

d

EMS2

3

SB

R / BL

5

1

2

4

4 1

P

2

a

P

b


The fuel system has a fuel bleeding pump that is used when the fuel system has to be bled. A manual fuel press switch is situated on the left side of the engine.

When the fuel press switch is activated the fuel bleeding pump starts to pump round the fuel.

P0014009 a Fuel pressure b Fuel bleeding pump (P) c Start d Fuel press switch

c

124 47701632 10-2010

p0013473

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30-2 Fault Tracing

Measurements

Checking the wiring

Tools:

9812519 Multimeter


2 Remove the wire to be measured from the preheat relay.

3 Remove connector B from the EMS2.

4 Use multimeter 9812519 to do a resistance measurement between connector B (see circuit description) to the loosen wire.

R ≈ 0Ω.

Checking supply cable, fuel sensor

Tools:

885675 Break out cable


9812519 Multimeter

1 NOTICE! Turn ignition off.

2 Disconnect the connector from the sensor.

3 TAD1250-1252 and TWD1643:

Connect adapter cable 885675 to the cable harness connector to the engine control unit.

TAD950-952 (with bleeding pump):


4 Use multimeter 9812519 for voltage measurement.

5 Turn ignition on.

Measurement points Nominal value

1 – 4 (no fuel bleeding pump) U ≈ 5 V

2 – 4 (with fuel bleeding pump) U ≈ 5 V

125

30-2 Fault Tracing p0013474

885675

Checking negative cable, fuel sensor

Tools:



9812519 Multimeter



3 TAD1250-1252 and TWD1643:


TAD950-952:


4 Use multimeter 9812519 to do resistance measurement against the engine control unit.

Measurement points

4 – Battery negative

(no fuel bleeding pump)


(with fuel bleeding pump)

Nominal value

R ≈ 0 Ω

R ≈ 0 Ω

NOTICE! Measurement is done to eliminate short circuiting or breaks in the cable to the engine control unit.

126 47701632 10-2010

p0013475

885 675

30-2 Fault Tracing

Checking the signal cable for interruption or shortcircuit

Tools:



9812519 Multimeter



3 TAD1250-1252 and TWD1643:


TAD950-952:


4 Remove connector B from the engine control unit.

5 Use multimeter 9812519 to do a resistance measurement against the engine control unit connector

B.


2(885675)– 16(EMS2, conn.B)


2(885675)– 18(EMS2, conn.B)


2(885675)– 17(EMS2, conn.B)


3(88890053) – 16(EMS2, conn.B)


3(88890053) – 18(EMS2, conn.B)


3(88890053) – 17(EMS2, conn.B)


Nominal value

R ≈ 0 Ω

R ≈ ∞ Ω

R ≈ ∞ Ω

R ≈ 0 Ω

R ≈ ∞ Ω

R ≈ ∞ Ω


IMPORTANT!

Be very careful when measuring inside the connector, to ensure that no pin is damaged.

47701632 10-2010 127

30-2 Fault Tracing p0013476

1

2

885675

3

4

5

3

4

V

Checking fuel pressure sensor

Tools:



9812519 Multimeter



3 TAD1250-1252 and TWD1643:

Connect adapter cable 885675 between the sensor and the engine control unit.

TAD950-952:

Connect adapter cable 88890053 between the sensor and the engine control unit.


5 Turn ignition on.


4–3


4–3


Nominal value

U ≈ 0,5 V

(at normal atmospheric pressure)

U ≈ 0,5 V

(at normal atmospheric pressure)

128 47701632 10-2010

p0013376

V

30-2 Fault Tracing

Checking supply cable, water in fuel switch

Tools:

9812519 Multimeter


2 Disconnect the connector from the switch.

3 Use multimeter 9812519 to do voltage measurement towards the engine control unit.

4 NOTICE! Turn ignition on.


Yellow conductor –

Black conductor

Nominal value

U ≈ Battery voltage x 0.8

47701632 10-2010 129

30-2 Fault Tracing

Checking negative cable, water in fuel switch

Tools:

9812519 Multimeter





Black conductor –

Battery negative

Nominal value

R ≈ 0 Ω

P0013419

130

Checking water in fuel switch

Tools:


9998699 Break-out box

9812519 Multimeter


2 Connect adapter cable 9990014 with measurebox

9998699 between EMS 2 (connector B) and the switch.


4 Turn ignition on.


10 - 8 Switch immersed in fuel

10 - 8 Switch immersed in water

Nominal value

U ≈ 0,8 x battery voltage

U ≈ 0,8 x battery voltage -

5 V

47701632 10-2010

P0013296

1

2

885675

3

4

5

1

2

30-2 Fault Tracing

Checking oil level sensor

Tools:


Tools:

9812519 Multimeter


2 Connect adapter cable (885675) to the sensor. Do not connect the other end of the adapter cable.

3 Use multimeter 9812519 to do resistance measurement.


1–2

Nominal value

R ≈ 10 – 14 Ω

NOTICE! Even if the nominal value is correct the sensor could be faulty.

47701632 10-2010 131

30-2 Fault Tracing

Checking supply cable, oil pressure sensor

Tools:


9812519 Multimeter


2 Remove the connector from the sensor. Connect adapter cable 885675 between the sensor and engine control unit.




1–4

Nominal value

U ≈ 5 V

P0001355

P0013657

132

4

885675

-

Checking negative cable, oil pressure sensor

Tools:


9812519 Multimeter



3 Connect adapter cable 885675 to the cable harness connector to the engine control unit.




Nominal value

R ≈ 0 Ω

47701632 10-2010

P0001266

P0013482

47701632 10-2010

30-2 Fault Tracing

Checking signal cable, oil pressure sensor

Tools:


9812519 Multimeter






2–4

Nominal value

R ≈ 80 – 120 kΩ


Checking oil pressure sensor

Tools:


9812519 Multimeter



3 Connect adapter cable 885675 between the sensor and the engine control unit.


5 Turn ignition on.


2–4

Nominal value

U ≈ 0,5 V (at normal atmospheric pressure)

133

30-2 Fault Tracing

885675

1

2

885675

3

4

5

1 2

V

V

Checking signal cable voltage, inlet manifold (pressure/)temperature sensor

Tools:


9812519 Multimeter





5 Turn ignition on.


1–2

Nominal value

U ≈ 5 V

1 Turn ignition off.


3 Turn ignition on.


1–2

Nominal value

U ≈ 0.5– 4.5 V (depended of the temperature)

1

2

885675

3

4

5

1 2

885675

P0013483

134 47701632 10-2010

P0013484

1

885675

-

30-2 Fault Tracing

Checking negative cable, inlet manifold pressure/temperature sensor

Tools:


9812519 Multimeter







Nominal value

R ≈ 0 Ω

47701632 10-2010 135

30-2 Fault Tracing

Checking the sensor cable for open circuit or shortcircuit

Inlet manifold temperature sensor

Tools:


9812519 Multimeter




4 Remove connector A from the engine control unit.

5 Use multimeter 9812519 to do a resistance measurement against engine control unit connector A.


2 (885675)– 47(EMS2, conn.A) R ≈ 0 Ω

2 (885675)– 11(EMS2, conn.A) R ≈ ∞ Ω

1 (885675)– 47(EMS2, conn.A) R ≈ ∞ Ω

1 (885675)– 11(EMS2, conn.A) R ≈ 0 Ω


IMPORTANT!


P0013485

136 47701632 10-2010

P0013486

1

2

885675

3

4

5

1 2

885675

30-2 Fault Tracing

Checking inlet manifold temperature sensor

Tools:


9812519 Multimeter





1–2

1–2

1–2

1–2

1–2

1–2

1–2

1–2

Nominal value

R ≈ 9426 Ω

+/- 470 Ω (vid -10° C)

R ≈ 5896 Ω

+/- 332 Ω (vid 0° C)

R ≈ 2511 Ω

+/- 109 Ω (vid 20° C)

R ≈ 1200 Ω

+/- 47 Ω (vid 40° C)

R ≈ 612 Ω

+/- 22 Ω (vid 60° C)

R ≈ 329 Ω

+/- 11 Ω (vid 80° C)

R ≈ 186 Ω

+/- 5 Ω (vid 100° C)

R ≈ 110 Ω

47701632 10-2010 137

30-2 Fault Tracing

V

Checking supply cable, inlet manifold pressure sensor

Tools:


9812519 Multimeter




4 Turn ignition on.


1–3

Nominal value

U ≈ 5 V

P0013487

1

2

885675

3

4

3

1

5

P0013488

1

2

885675

3

4

5

4

1

885675

Checking signal cable, inlet manifold pressure sensor

Tools:


9812519 Multimeter






4–1

Nominal value

R ≈ 80 – 120 k Ω


138 47701632 10-2010

P0013489

1

4

P0013494

1

2

47701632 10-2010

30-2 Fault Tracing

Checking air inlet pressure sensor

Tools:


9812519 Multimeter





5 Turn ignition on.


1–4

Nominal value

U ≈ 1,1 V (at normal atmospheric pressure)

Checking supply cable, air filter pressure switch

Tools:


9812519 Multimeter



3 Connect adapter cable 885675 between the switch and engine control unit.




1–2

Nominal value

U ≈ 2.9 V



1–2

Nominal value

U ≈ 0.8 x battery voltage

139

30-2 Fault Tracing

P0013496

1

2

885675

3

4

5

1

2

885675

Checking air pressure switch

Tools:


9812519 Multimeter



Do not connect the other end of the adapter cable.

3 Connect adapter cable 885675 to the switch.

4 Use multimeter 9812519 for resistance measurement.


1–2

Nominal value

R ≈ 330 Ω

NOTICE! If the measured value is 2.2 kOhm when the engine is shut down the switch inside is stuck in active position.

140 47701632 10-2010

P0004935

1

2

885675

3

4

5

1

2

885 675

30-2 Fault Tracing

Checking coolant temperature sensor

Tools:


9812519 Multimeter


2 Connect adapter cable (885675) to the sensor.




1–2

1–2

1–2

1–2

1–2

1–2

1–2

1–2

Nominal value

R ≈ 9397 Ω

+/- 755 Ω (at -10° C)

R ≈ 5896 Ω

+/- 430 Ω (at 0° C)

R ≈ 2500 Ω

+/- 148 Ω (at 20° C)

R ≈ 1175 Ω

+/- 56 Ω (at 40° C)

R ≈ 596 Ω

+/- 22 Ω (at 60° C)

R ≈ 323 Ω

+/- 10 Ω (at 80° C)

R ≈ 186 Ω

+/- 5 Ω (at 100° C)

R ≈ 113 Ω

47701632 10-2010 141

30-2 Fault Tracing

P0004936

1

2

3

1

5

1

2

885675

3

4

5

2

885675

B

4

8

16

20

24

28

40

44

48

52

56

52

1

5

9

13

17

21

25

37

41

45

49

53

60


Coolant temperature sensor

Tools:


9812519 Multimeter






B.


2 (885675)– 27 (EMS2, conn.B)

2 (885675)– 18 (EMS2, conn.B)

1 (885675)– 27 (EMS2, conn.B)

1 (885675)– 18 (EMS2, conn.B)

Nominal value

R ≈ 0 Ω

R ≈ ∞ Ω

R ≈ ∞ Ω

R ≈ 0 Ω


IMPORTANT!


B

142 47701632 10-2010

47701632 10-2010

30-2 Fault Tracing

Checking supply cable, coolant level switch

Tools:


9812519 Multimeter







1–2

Nominal value

U ≈ Battery voltage x 0.8

Checking negative cable, coolant level switch

Tools:


9812519 Multimeter







Nominal value

R≈ 0 Ω

143

P0001265

144

30-2 Fault Tracing

Checking coolant level switch

Tools:

9812519 Multimeter

NOTICE! The coolant level switch can be removed without having to drain the coolant.

1 Undo the connector and remove the switch from the expansion tank.

2 Use multimeter 9812519 to do resistance measurement against the switch.


Blue – Black

Nominal value

R ≈ ∞ Ω

3 Move a magnet along the switch and observe the resistance value. The resistance should drop to approx. 0 Ohm.


Blue – Black

Nominal value

R ≈ 0 Ω

Checking crankcase pressure sensor

Tools:


9812519 Multimeter





5 Turn ignition on.


2–4

Nominal value

U ≈ 2.9 V (at normal atmospheric pressure)

47701632 10-2010

P0013499

1

2

885675

3

4

5

3

4

30-2 Fault Tracing

Checking signal cable, air filter temperature switch

Tools:


9812519 Multimeter







3–4

Nominal value

U ≈ 5 V



3 Turn ignition on.


3–4

Nominal value

U ≈ 0.5 – 4.5 V (depended of the temperature)

P0013500

1

2

885675

3

4

5

3

4

47701632 10-2010 145

30-2 Fault Tracing

Checking negative cable, air filter temperature switch

Tools:


9812519 Multimeter






3 — Battery negative

Nominal value

R ≈ 0 Ω

P0013501

1

2

885675

3

4

5

3

146 47701632 10-2010

1

2

885675

3

4

5

3

P0013502

1

2

885675

3

4

5

4

885 675

B

4

8

16

20

24

28

40

44

48

56

52

B

1

5

9

13

17

21

25

37

41

45

53

60

30-2 Fault Tracing


Air filter temperature sensor

Tools:


9812519 Multimeter






B.


4 (885675) – 31(EMS2, conn.B)

4 (885675) – 18(EMS2, conn.B)

3 (885675) – 31(EMS2, conn.B)

3 (885675) – 18(EMS2, conn.B)

Nominal value

R ≈ 0 Ω

R ≈ ∞ Ω

R ≈ ∞ Ω

R ≈ 0 Ω


IMPORTANT!


47701632 10-2010 147

30-2 Fault Tracing

P0013503

1

2

885675

3

4

5

3

4

885 675

Checking air inlet temperature sensor

Tools:


9812519 Multimeter


2 Connect adapter cable (885675) to the sensor.




3–4

3–4

3–4

3–4

3–4

3–4

Nominal value

R ≈ 16445 Ω

+/- 822 Ω (at 0°C)

R ≈ 5000 Ω

+/- 220 Ω (at 25°C)

R ≈ 4027 Ω

+/- 160 Ω (at 30°C)

R ≈ 1247 Ω

+/- 40 Ω (at 60°C)

R ≈ 463 Ω

+/- 19 Ω (at 90°C)

R ≈ 199 Ω

+/- 10 Ω (at 120°C)

Checking signal cable, exhaust gas temperature sensor

Tools:

9812519 Multimeter


2 Remove the connector from the sensor.




1–2

Nominal value

U ≈ 5 V

148 47701632 10-2010

47701632 10-2010

30-2 Fault Tracing

Checking negative cable, exhaust gas temperature sensor

Tools:

9812519 Multimeter





1 — Battery negative

Nominal value

R ≈ 0 Ω

Checking exhaust gas temperature sensor

Tools:

9812519 Multimeter


2 Remove the connector from the sensor and remove the sensor from exhaust bend to check that the sensor has no visible damage.

3 Use multimeter 9812519 to measure resistance between the two contact pins on the sensor. The resistance shall agree with the values in the chart.

Measurement value points

Nominal resistance value

1–2

1–2

1–2

1–2

1–2

1–2

1–2

1–2

R ≈ 185 Ω at -20° C

R ≈ 200 Ω at 0° C

R ≈ 220 Ω at 25° C

R ≈ 238 Ω at 50° C

R ≈ 276 Ω at 100° C

R ≈ 313 Ω at 150° C

R ≈ 349 Ω at 200° C

R ≈ 385 Ω at 250° C

Nominal voltage measured over the sensor

U ≈ 0.78 V at -20° C

U ≈ 0.84 V at 0° C

U ≈ 0.90 V at 25° C

U ≈ 0.96 V at 50° C

U ≈ 1.08 V at 100° C

U ≈ 1.19 V at 150° C

U ≈ 1.29 V at 200° C

U ≈ 1.39 V at 250° C

149

30-2 Fault Tracing

1–2

1–2

1–2

1–2

1–2

1–2

1–2

1–2

1–2

1–2

R ≈ 420 Ω at 300° C

R ≈ 454 Ω at 350° C

R ≈ 488 Ω at 400° C

R ≈ 521 Ω at 450° C

R ≈ 554 Ω at 500° C

R ≈ 618 Ω at 600° C

R ≈ 679 Ω at 700° C

R ≈ 738 Ω at 800° C

R ≈ 795 Ω at 900° C

R ≈ 849 Ω at 1000° C

Checking negative cable, oil temperature switch

Tools:


9812519 Multimeter







Nominal value

R ≈ 0 Ω

U ≈ 1.48 V at 300° C

U ≈ 1.56 V at 350° C

U ≈ 1.64 V at 400° C

U ≈ 1.71 V at 450° C

U ≈ 1.78 V at 500° C

U ≈ 1.91 V at 600° C

U ≈ 2.02 V at 700° C

U ≈ 2.12 V at 800° C

U ≈ 2.21 V at 900° C

U ≈ 2.30 V at 1000° C

P0013506

1

2

885675

3

4

5

4

150 47701632 10-2010

1

2

885675

3

4

5

3

4

V

V

30-2 Fault Tracing

Checking signal cable, oil temperature switch

Tools:


9812519 Multimeter





5 Turn ignition on.


3–4

Nominal value

U ≈ 5 V



3 Turn ignition on.


3–4

Nominal value

U ≈ 0.5-4.5 V (depended of the temperature)

P0013507

1

2

885675

3

4

5

3

4

47701632 10-2010 151

30-2 Fault Tracing

Checking oil temperature sensor

Tools:


9812519 Multimeter





3–4

3–4

3–4

3–4

3–4

3–4

3–4

Nominal value

R ≈ 4981 Ω

+/- 503 Ω (at 0°C)

R ≈ 1900 Ω

+/- 163 Ω (at 20°C)

R ≈ 809 Ω

+/- 59 Ω (at 40°C)

R ≈ 378 Ω

+/- 24 Ω (at 60°C)

R ≈ 191 Ω

+/- 10 Ω (at 80°C)

R ≈ 104 Ω

+/- 5 Ω (at 100°C)

R ≈ 60 Ω

+/- 3 Ω (at 120°C )

P0013508

152 47701632 10-2010

P0013509

30-2 Fault Tracing

Checking starter motor relay

Tools:

9812519 Multimeter

1 NOTICE! Turn off the main switch.

2 Undo the red/yellow cable on the startermotor.

3 Use multimeter 9812519 to do resistance measurement towards the relay.

Nominal value

R ≈ 8 – 14 Ω

Checking negative cable, air filter pressure switch

Tools:


9812519 Multimeter







Nominal value

R ≈ 0 Ω

P0013495

1

2

885675

3

4

5

1

47701632 10-2010 153

30-2 Fault Tracing

V

P0013510

1

2

8

3

9

15

4

10

16

22

9998699

6

5

12

11

18

17

24

23

30

29

36

7

13

19

25

31

37

43

14

20

26

32

38

44

50

21

27

33

39

45

51

57

28

34

40

46

52

58

35

41

47

53

59

42

48

54

60

49

55

61

56

62

Checking stop signal cable between

ECU and CIU/DCU

Tools:



9812519 Multimeter



9998699 between the engine and the CIU/DCU.

Use the engine connector.


4 Turn ignition on.

Measurement points in measurebox

Nominal value

18 – 21 (energized to stop) U ≈ 0,8 x battery voltage

18 – 21 (energized to run) U ≈ Battery voltage

154 47701632 10-2010

885 675

1

2

885675

3

4

5

1

2

V

V

30-2 Fault Tracing

Checking signal cable, coolant temperature switch

Tools:


9812519 Multimeter







1–2

Nominal value

U ≈ 5 V



3 Turn ignition on.


1–2

Nominal value

U ≈ 0.5 – 4.5 V (depended of the temperature)

P0004938

885 675

1

2

885675

3

4

5

1

2

47701632 10-2010 155

30-2 Fault Tracing

Checking negative cable, coolant temperature switch

Tools:


9812519 Multimeter







Nominal value

R ≈ 0 Ω

P0004937

1

2

885675

3

4

5

1

885675

Checking negative cable, piston cooling oil temperature switch

Tools:


9812519 Multimeter


2 Undo the connector from the switch. Connect the adapter cable (9998534) to the cable harness connector that is connected to the engine control unit.

3 Use the multimeter (9812519) to do resistance measurement against the engine control unit.



Nominal value

R ≈ 0 Ω

P0013512

1

2

885675

3

4

5

2

885675

156 47701632 10-2010

30-2 Fault Tracing

Checking supply cable, piston cooling oil temperature switch

Tools:


9812519 Multimeter

1 NOTICE! Turn the starter key to the stop position.

2 Undo the connector from the switch. Connect the adapter cable (9998534) to the cable harness connector that is connected to the engine control unit.

3 Use multimeter (9812519) for voltage measurement.

4 Turn the starter key to position I (drive position).


1–2

Nominal value

U ≈ 0.8 x Battery voltage

P0013513

1

2

885675

3

4

5

1

2

885675

Checking the IEGR coil

Tools:



9812519 Multimeter



9998699 between EMS 2 (connector B) and the

IEGR.

3 Use multimeter 9812519 to measure the resistance in the IEGR coil and cable harness.


30 – 60

Nominal value

R ≈ 33 – 49 Ω

47701632 10-2010 157

30-2 Fault Tracing

Checking IEGR solenoid


2 Remove the IEGR solenoid. Please see workshop manual Group 21-26 for reference how to remove the IEGR solenoid.

3 One part of the solenoid is spring loaded. Press gently down that part with a screwdriver and hold.

4 Connect a 24 volt power supply to the IEGR electrical connection. The solenoid should now make a click when alter its position and one should feel a pressure in the screwdriver.

P0013517

VOL

TS

158 47701632 10-2010

47701632 10-2010

P0013521

30-2 Fault Tracing

Checking supply cable, coldstart valve

Tools:


9812519 Multimeter


2 Remove the connector from the valve. Connect adapter cable 885675 between the valve and engine control unit.


4 Turn ignition on.


1 - 4 (valve activated)

Nominal value

U ≈ battery voltage

1 - 4 (valve not activated) U ≈ 0V

159

30-2 Fault Tracing

Checking negative cable, coldstart valve

Tools:


9812519 Multimeter


2 Disconnect the connector from the valve.

3 Connect adapter cable 885675 to the valve.




Nominal value

R ≈ 0 Ω

Also do a continuity test between 1 - 4 to verify that the coil inside the valve is intact.

P0013522

160 47701632 10-2010

47701632 10-2010

30-2 Fault Tracing

Trimming the injector

The electronic trim strategy is used to ensure that all injectors run with nominal timing and fuel delivery. This is achieved by adjusting the beginning and end of the electronic drive waveform for each actuator to compensate for spread in actuation and deactuation times of the two actuators in each injectors and to correct for variations in fuelling due to nozzle flow variations.

NOTICE! Write down the new injector’s code before installation. The code consists of 9 characters and is on the injector’s electric connector under the SN number.

1 Connect Vodia and switch on the current for the engine.

2 Go into the ”Service and maintenance” menu in

Vodia.

3 Select ”Parameter, programming”.

4 Press ”Play”.

5 Select the cylinder number corresponding to the injector which has been changed.

6 Enter the new injector’s code. Click ”OK”.

7 Close ”Parameter, programming”.

8 Vodia will ask you to ”Turn off the main switch”, then follow the instructions.

9 Report the parameters back as in items 10 - 13 in ”Programming the control unit”.

161

30-2 Fault Tracing

P0013524

A

4

8

16

20

24

28

40

44

48

52

56

52

A

1

5

9

13

17

21

25

37

41

45

49

53

60

Checking the injector wiring

Tools:

9812519 Multimeter

1 NOTICE! Turn the starter key to the stop position.

2 Turn the main switch off.

IMPORTANT!

The system must be disconnected from system voltage and the starter key must be in position 0 when the engine control unit connector is disconnected or connected.

3 Remove the connector from the engine control unit.

Move the lock catch (1) upwards and pull the connector (2) out.

4 Use multimeter 9812519 to measure the resistance in the engine cable’s black (upper) connector for the injectors.

IMPORTANT!


NOTICE! The measurement should exclude short circuiting or open circuit in the cable to the injector.

Measurement points in connector A

20 – 62 Cylinder 1

Nominal value

12 – 62

28 – 62

24 – 59

16 – 59

32 – 59

52 – 61

44 – 61

36 – 61

56 – 60

48 – 60

40 – 60

Cylinder 2

Cylinder 3

Cylinder 1

Cylinder 2

Cylinder 3

Cylinder 4

Cylinder 5

Cylinder 6

Cylinder 4

Cylinder 5

Cylinder 6

R ≈ 1.4 – 3 Ω

( at 20° C )

R ≈ 1.4 – 3 Ω

( at 20° C )

R ≈ 1.4 – 3 Ω

( at 20° C )

R ≈ 1.4 – 3 Ω

(at 20° C )

R ≈ 1.4 – 3 Ω

( at 20° C )

R ≈ 1.4 – 3 Ω

( at 20° C )

R ≈ 1.4 – 3 Ω

( at 20° C )

R ≈ 1.4 – 3 Ω

( at 20° C )

R ≈ 1.4 – 3 Ω

( at 20° C )

R ≈ 1.4 – 3 Ω

( at 20° C )

R ≈ 1.4 – 3 Ω

( at 20° C )

R ≈ 1.4 – 3 Ω

(at 20° C )

162 47701632 10-2010

30-2 Fault Tracing

Checking IEGR wiring


2 Remove the valve cover.

3 Remove the connector from the IEGR solenoid.


5 Use multimeter 9812519 to do a resistance measurement between connector B from the EMS2 to the loosend connector.


B30 – 1 (IEGR connector) R ≈ 0 Ω



B30 – 2 (IEGR connector) R ≈ ∞ Ω



IMPORTANT!


47701632 10-2010 163

30-2 Fault Tracing

885675

1

2

885675

3

4

5

1 2

P0013526

1

2

885675

3

4

5

2

B

4

8

16

20

24

28

40

44

48

52

56

52

B

1

5

9

13

17

21

25

37

41

45

49

53

60

Checking camshaft sensor wiring

Tools:


9812519 Multimeter


2 Remove the connector from the sensor. Connect adapter cable 885675 to the connector.

3 Remove connector A from the EMS2.

4 Use multimeter 9812519 to do a resistance measurement from the sensor connector to connector A to verify that neither of the wires are broken or short circuited.


1 (sensor conn.) – 38 (conn. A)


1 (sensor conn.) – 2 (sensor conn.)

Nominal value

R ≈ 0 Ω

R ≈ 0 Ω

R ≈ ∞ Ω

IMPORTANT!


164 47701632 10-2010

885 675

1

2

885675

3

4

5

1 2

P0008931

885 675

1

2

885675

3

4

5

1 2

V

30-2 Fault Tracing

Checking camshaft sensor

Tools:


9812519 Multimeter


2 Undo the connector from the sensor and remove the sensor from the cylinder head.

Check that the sensor does not have any external damage, or any swarf which has got stuck on it.

3 Connect adapter cable 885675 to sensor.

NOTICE! Do not connect the other end of the adapter cable to the engine cable harness, since this can cause a measurement error.



1 – 2

Nominal value

R ≈ 0,9 kΩ at 20°C

5 Use multimeter 9812519 for a AC voltage measurement.

Move a metal object rapidly back and forwards not more than 1 mm in front of the sensor. Check that the multimeter gives a reading.

6 Install the sensor.

47701632 10-2010 165

30-2 Fault Tracing

885675

1

2

885675

3

4

5

1 2

P0013527

1

2

885675

3

4

5

2

B

4

8

16

20

24

28

40

44

48

52

56

52

B

1

5

9

13

17

21

25

37

41

45

49

53

60

Checking flywheel sensor wiring

Tools:


9812519 Multimeter


2 Remove the connector from the sensor. Connect adapter cable 885675 to the connector.

3 Remove connector A from the EMS2.

4 Use multimeter 9812519 to do a resistance measurement from the sensor connector to connector A to verify that neither of the wires are broken or short circuited.




1 (sensor conn.) – 2 (sensor conn.)

Nominal value

R ≈ 0 Ω

R ≈ 0 Ω

R ≈ ∞ Ω

IMPORTANT!


166 47701632 10-2010

885 675

1

2

885675

3

4

5

1 2

P0008931

885 675

1

2

885675

3

4

5

1 2

V

30-2 Fault Tracing

Checking flywheel sensor

Tools:


9812519 Multimeter


2 Undo the connector from the sensor and remove the sensor from the cylinder head.

Check that the sensor does not have any external damage, or any swarf which has got stuck on it.

3 Connect adapter cable 885675 to sensor.




1–2

Nominal value

R ≈ 0,9 kΩ at 20°C

5 Use multimeter 9812519 for a AC voltage measurement.

Move a metal object rapidly back and forwards not more than 1 mm in front of the sensor. Check that the multimeter gives a reading.

6 Install the sensor.

47701632 10-2010 167

168

30-2 Fault Tracing

Checking negative cable, wastegate valve

Tools:


9812519 Multimeter


2 Disconnect the connector from the wastegate regulator(1).




7 – Battery negative(B-) R ≈ 0 Ω

47701632 10-2010

47701632 10-2010

30-2 Fault Tracing

Checking supply cable, wastegate valve

Tools:


9812519 Multimeter


2 Remove the connector from the wastegate regulator.

3 Connect adapter cable 88890053 between the wastegate regulator and engine control unit.




1 – 7

Nominal value

U ≈ Battery voltage

169

30-2 Fault Tracing

Checking the wastegate valve

Tools:


9812519 Multimeter


2 Remove the connector from the wastegate valve.

Connect adapter cable 885675 to the valve.


3 Use multimeter 9812519 to check the resistance in the wastegate valve.

NOTICE! Measurement is done to eliminate short circuiting or breaks in the wastegate valve.


1–2

Nominal value

R = 90 ± 4.5 Ω at 20 °C (68°F)

170 47701632 10-2010

P0013535

1

2

8

3

9

15

4

10

16

22

9998699

6

5

12

11

18

17

24

23

30

29

36

7

13

19

25

31

37

43

14

20

26

32

38

44

50

21

27

33

39

45

51

57

28

34

40

46

52

58

35

41

47

53

59

42

48

54

60

49

55

61

56

62

30-2 Fault Tracing

Checking preheater relay

Tools:


9812519 Multimeter



3 Connect adapter cable 9990014 between connector B and engine control unit.




B7 – B59

Nominal value

U ≈ 0 V

If there is an open circuit in the sense wiring circuit the multimeter will show:


B7 – B59

Fault value

U ≈ 19.5 V

Checking CAN bus cable

Tools:



9812519 Multimeter

The resistance of the CAN bus termination resistors, one 120 Ω resistor in the ECU and one 120 Ω resistor in the cable harness, are measured.


2 Disconnect the 8-pin Deutsch connector at the

DCU or disconnect at the CIU.

3 Connect measurebox 9998699 with adaptercable

88890016 between the engine control unit and the

DCU.

4 Use multimeter 9812519 to do resistance measurement towards the EMS 2.


16–17

Nominal value

U ≈ 60 Ω

47701632 10-2010 171

30-2 Fault Tracing

29 15 1

43 28 14

11

or

Measurement points in the CIU connector

11–12

Nominal value

U ≈ 60 Ω

NOTICE! Even if the measured value equals the nominal value the data bus cable could be faulty due to short circuit between a data bus cable and another cable in the harness.

P0013536

P0013537

172

1

2

8

3

9

15

4

10

16

22

9998699

6

5

12

11

18

17

24

23

30

29

36

7

13

19

25

31

37

43

14

20

26

32

38

44

50

21

27

33

39

45

51

57

28

34

40

46

52

58

35

41

47

53

59

42

48

54

60

49

55

61

56

62

V


9998699 between the EMS 2 and the CIU/DCU.

2 Use multimeter 9812519 to a voltage measurement.

Measurement points in the measurebox

16 (CAN-H) –

18 (power supply 0V)

17 (CAN-L) –

18(power supply 0V)

Nominal value

U ≈ 2.3 V – 2.7 V

U ≈ 2.3 V – 2.7 V


47701632 10-2010

47701632 10-2010

30-2 Fault Tracing

Checking the CAN bus cable

Tools:

9812519 Multimeter



The resistance of the CAN bus termination resistors, one 120 Ω resistor in the ECU and one 120 Ω resistor in the cable harness, are measured.


2 Disconnect the 8-pin Deutsch connector at the

DCU or disconnect at the CIU.

3 Use multimeter 9812519 to do resistance measurement towards the EMS 2.

Measurement points in the engine connector at the DCU

1–2

Nominal value

U ≈ 60 Ω

or

Measurement points in the CIU connector

11–12

Nominal value

U ≈ 60 Ω



9998699 between the EMS 2 and the CIU/DCU.

2 Use multimeter 9812519 to a voltage measurement.

Measurement points in the measurebox

16 – 17 (between CAN bus)

Nominal value

U ≈ 2.3 V – 2.7 V


173

P0001266

174

30-2 Fault Tracing

P0001264

Checking negative cable, crankcase pressure sensor

Tools:


9812519 Multimeter







Nominal value

R ≈ 0 Ω

Checking signal cable, crankcase pressure sensor

Tools:


9812519 Multimeter






2 – 4

Nominal value

R ≈ 80 -120 kΩ


47701632 10-2010

30-2 Fault Tracing

Checking supply cable, crankcase pressure sensor

Tools:


9812519 Multimeter






1 – 4

Nominal value

U ≈ 5 V

P0001355

47701632 10-2010

Vodia logging throttle signal

To verify the throttle signal on the J1587 bus do as follow:

1 Choose “Log test” under the “Service and maintenance” menu.

2 Choose “MID 128, Accelerator Pedal Position” and

“MID 144, Throttle Calibrated Position” and press play.

3 Verify that booth throttle values displayed in percentage by Vodia changes simultaneous while moving the throttle.

175

P0012802

176

37-0 Wiring Diagrams

37-0 Wiring Diagrams

TAD940-41GE, TAD940-43

R 1,5

GR/GN

BN/OR

SB 1,5

GR/OR

OR/SB

GR/SB

GR/SB

VO/SB

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

BL/OR

LBN

GN/SB

GN/W

SB 1,5

Y

BL/W

BL/GR

GN/R

R 1,5

GN/BL

SB 1,5

W 1,5

W 1,5

Y/SB

W/SB

W

GR/SB

R/BL 1,5

SB 1,5

GR/W

R/BL 1,5

R/BL 1,5

OR

R/Y

Y/W

GR/Y

SB 1,5

SB 1,5

SB 1,5

CAN 2

SB 2,5

R/Y

R/BL

R 2,5 R 1,5

W/SB

SB 1,5

W

Y/W

GR/Y

SB 2,5

R 2,5

R/BL 1,5

GR/SB

W

W/SB

47701632 10-2010

1 Battery

2 Starter motor

3 Alternator

4 Main relay

5 Stop switch

6 Control unit EDC

7 Sensor, coolant level

8 Sensor, coolant temperature

9 Sensor, air inlet pressure / inlet manifold temperature

10 Sensor, oil pressure

11 Sensor, oil level / oil temperature

12 Sensor, crankcase pressure

13 Sensor, camshaft

14 Sensor, flywheel

15 Sensor, fuel pressure

16 Unit injector (Cyl. 1-6)

17 Connector - engine interface

18 Connector - application tool

19 Connector - serial J1587

20 AUX STOP

21 Jumper - removeable

22 Fuse 10A

23 Switch - fuel pump

24 Switck - water in fuel

25 Connector - remote water in fuel

26 Pre-heater

27 Pre-heater relay

28 Fuel pump


Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow

Cable cross section = 0.75 mm

2

unless otherwise stated.

47701632 10-2010 177


TAD950-952VE

1 3

SB 2,5

SB 16

R/Y

R/BL

R 2,5

1 3

R 1,5

SB 1,5

4 2

BN/OR

GR/GN

GR/OR

OR/SB

GR/SB

GR/SB

VO/SB

W 1,5 36

W 1,5 40

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

BL/OR

GR/R

LBN

GN/SB

GN/W

SB1,5

Y

GN/R

W 1,5

W 1,5 62

W 1,5

W 1,5 61

Y/SB

W/SB

VO/SB

GR/SB

R/BL 1,5

SB 1,5

R 1,5

GN/BL

SB 1,5

(2) SB

GR/W

BL/W

BL/GR

GN 1,0

CAN 2

R/BL 1,5

R/BL 1,5

SB 1,5

SB 1,5

SB 1,5

Y/W

GR/Y

OR

R/Y

CAN j1939

(2) SB

Y/W

GR/Y

SB 2,5

R 2,5

R/BL 1,5

GR/SB

VO/SB

W/SB

R 2,5

P0014016

178 47701632 10-2010

1 Switch, piston cooling

2 Switch, coolant level

3 Sensor, oil temperature and oil level

4 Switch, water in fuel


6 Sensor, fuel pressure / fuel temp.

7 Switch for electric feed pump switch


9 Internal EGR

10 Extra stop

11 J1939 CAN (bus)

12 Battery negative

13 Battery plus

14 Voltage after key

15 Connection for stop button

16 J1587 / 1708 (bus)

17 Diagnostic outlet

18 Relay socket

19 Main relay

20 Main circuit breaker 10 A

21 Relay pre-heating

22 Pre-heating

23 Battery (24 V)

24 Starter motor

25 Alternator


27 Sensor, flywheel

28 Sensor, camshaft


30 Sensor, air inlet pressure / temperature

31 Connector block B

32 Connector block A

33 Control unit EMS 2


Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


47701632 10-2010 179


TAD1250-1252VE

R/BL 1,5

W 1,5 59

W 1,5

W 1,5

W 1,5 61

Y/SB

W/SB

W

BL

R/BL 1,5

SB 1,5

GR/OR

SB 1,0-

R 1,0+

BN/OR

GR/GN

SB

OR

OR/SB

GR/SB

GR/SB

VO/SB

W 1,0 36

W 1,0

W 1,0

W 1,0 48

W 1,0

W 1,0

W 1,0

W 1,0

W 1,0 12

W 1,0

W 1,0

W 1,0 24

GN/SB

GN/W

BL/GN

BL/OR

GN/R

R 1.0

SB 1.0

GR/R

BN/OR

LBN

GR/R

SB1,0

Y

BL/W

BL/GR

GN 1.0

R/Y

OR

R/BL 1,5

R/BL 1,5

SB 1,5

SB 1,5

SB 1,5

Y/W

GR/Y

SB 2,5

R 2,5

3 4

P0014017

SB 2,5

R/Y

R 2,5

Y/W

GR/Y

SB 2,5

R 2,5

R/BL 1,5

BL

W

W/SB

180 47701632 10-2010







7 Switch, piston cooling pressure


9 Connector block (not used)

10 Internal EGR

11 Extra stop

12 J1939 CAN (bus)

13 Battery negative

14 Battery plus


16 Stop button

17 J1587 / J1708 (bus)

18 Diagnostic tool

19 Main relay



22 Starter motor

23 Battery (24 V)

24 Pre-heating

25 Alternator


27 Sensor, flywheel

28 Sensor, camshaft

29 Sensor, air inlet pressure / temperature


31 Connector block B

32 Connector block A



Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


47701632 10-2010 181


TAD1350-1352GE

n 2 1 n 2 1

R/BL 1,5

SB 2,5

R/W

Y/SB

R 2,5

BN 1,0

R/BL 1,0

OR 1,0

GR/OR

SB 1,0

R 1,0

BN/OR

GR/GN

SB

OR

OR/SB

GR/SB

GR/SB

VO/SB

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y/SB

W/SB

W

BL

R/BL 1,5

SB 1,5

Y 1,0

Y 1,0

Y 1,0

Y 1,0

GR/R

BN/OR

LBN

GR/R

Y

BL/W

BL/GR

Y 1,0

GN

Y/SB

OR 1,0

R/W

R/BL 1,5

R/BL 1,5

BN 1,0

SB 1,5

SB 1,5

SB 1,5

Y/W

GR/Y

GN/SB

GN/W

BL/GN

BL/OR

GN/R

R 1,0

SB 1,0

SB 2,5

R 2,5

R/BL

Y 1,0

SB

Y

SB

Y

CAN 2

Y/W

GR/Y

SB 2,5

R 2,5

R/BL 1,5

BL

W

W/SB

J1587 1708

R

W/SB

SB

W

182

P0014018

47701632 10-2010

1 Battery

2 Main switch

3 Starter motor

4 Alternator

5 Main relay

6 Aux stop

7 Connector, engine interface



10 VODIA input (diagnosis conn.)

11 Connector, development tool (not used)


13 Sensor, camshaft

14 Sensor, flywheel



17 Relay preheating

18 Fuse, preheating


20 Preheater







27 Connector, remote stop

28 Jumper removable

29 EGR internal

30 Control unit EMS 2.2

31 Wastegate valve


Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


47701632 10-2010 183


TAD1353–55GE

R/BL 1,5

SB 2,5

R/W

Y/SB

R 2,5

BN 1,0

R/BL 1,0

OR 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y/SB

W/SB

W

BL

R/BL 1,5

SB 1,5

GR/OR

SB 1,0

R 1,0

BN/OR

GR/GN

SB

OR

OR/SB

GR/SB

GR/SB

VO/SB

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

GR/R

BN/OR

LBN

GR/R

SB 1,0

Y

BL/W

BL/GR

Y 1,0

GN

Y/SB

OR 1,0

R/W

R/BL 1,5

R/BL 1,5

BN 1,0

SB 1,5

SB 1,5

SB 1,5

Y/W

GR/Y

GN/SB

GN/W

BL/GN

BL/OR

GN/R

R 1,0

SB 1,0

R/BL

Y 1,0

SB 2,5

R 2,5

P0012806

184

CAN 2

Y/W

GR/Y

SB 2,5

R 2,5

R/BL 1,5

BL

W

W/SB

R

W/SB

SB

W

47701632 10-2010

1 Battery

2 Main switch

3 Starter motor

4 Alternator

5 Main relay

6 Aux stop







13 Sensor, camshaft

14 Sensor, flywheel



17 Relay preheating

18 Fuse, preheating


20 Preheater








28 Jumper removable

29 EGR internal


31 Wastegate valve


Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


47701632 10-2010 185


TAD1341-45GE, TAD1340-45VE Visco fan

R

GR/OR

SB 1,0

R 1,0

BN/OR

GR/GN

SB

OR

GN

BL

OR/SB

GR/SB

GR/SB

VO/SB

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

BN 1,0

GN/SB

GN/W

BL/GN

BL/OR

GN/R

R 1,0

SB 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y/SB

W/SB

W

BL

R/BL 1,5

SB 1,5

GR/R

BN/OR

LBN

GR/R

SB 1,0

Y

BL/W

BL/GR

Y 1,0

GN

Y/SB

OR 1,0

R/W

R/BL 1,5

R/BL 1,5

BN 1,0

SB 1,5

SB 1,5

SB 1,5

Y/W

GR/Y

R/BL 1,5

SB 2,5

R/W

Y/SB

R 2,5

BN 1,0

R/BL 1,0

OR 1,0

SB 2,5

R 2,5

R/BL 1,0

P0012805

186

R/BL

Y 1,0

R/BL 1,5

CAN 2

Y/W

GR/Y

SB 2,5

R 2,5

R/BL 1,5

BL

W

W/SB

R

W/SB

SB

W

47701632 10-2010

1 Battery

2 Main switch

3 Starter motor

4 Alternator

5 Main relay

6 Aux stop







13 Sensor, camshaft

14 Sensor, flywheel



17 Relay preheating

18 Fuse, preheating


20 Preheater








28 Jumper removable

29 EGR internal


31 Wastegate valve

32 Visco elecric fan


Visco electric fan

A = Fan speed sensor supply

B = Clutch contol high

C = Clutch control low

D = Fan speed sensor ground

E = Fan speed output

F = Not connected

Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


47701632 10-2010 187


TWD1643GE

SB 70

R 70

W

SB

W/SB

R n 2

1 3 1 3 1 3 1 3 1 3 1 3

R 1,0

SB 1,0

SB

OR

BN/OR

GR/GN

GR/OR

OR/SB

GR/SB

GR/SB

VO/SB

W 1,0

W 1,0

W 1,0

W 1,0

W 1,0

W 1,0

W 1,0

W 1,0

W 1,0

W 1,0

W 1,0

W 1,0

W 1,5

W 1,5

W 1,5

W 1,5

GR/SB

W/SB

W

R/BL 1,5

SB 1,5

R/BL 1,5

R/BL 1,5

BN 1,0

Y/W

GR/Y

BL/W

BL/GR

SB 1,5

SB 1,5

SB 1,5

GR/R

BL/GN

BN/Y

LBL

GR

SB1,0

Y

VO

GN

BL/OR

GN/SB

GN/W

GN/R

BN/OR

R 1,0

SB 1,0

(2) SB

R

SB

SB

SB

R/BL

SB

Y

GR/SB

R 2,5

R/BL 1,5

SB 2,5

SB

Y

BN 1,0

R/ BL 1,0

OR 1,0

CAN 2

SB 2,5

R/BL 1,5

R/Y 1,0

R 2,5

R 2,5

SB 2,5

R 2,5

P0014019

188 47701632 10-2010








8 Connector (not used)

9 Extra stop

10 J1939 CAN (bus)

11 Battery negative

12 Battery plus


14 Stop button (press button)

15 J1587 (bus)

16 Jumper

17 Aux stop


19 Main relay


21 Starter motor

22 Battery (24 V)

23 Alternator

24 Pre-heating

25 Relay pre-heating


27 Sensor, flywheel

28 Sensor, camshaft




32 Thermostat by-pass valve

33 Wastegate valve

34 Sensor, exhaust temperature

35 Connector A

36 Connector B

37 Control module EMS 2


Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


47701632 10-2010 189


TAD1650VE

R/BL 1,5

SB 2,5

R/W

Y/SB

R 2,5

BN 1,0

R/BL 1,0

OR 1,0

GR/OR

SB 1,0

R 1,0

BN/OR

GR/GN

OR/SB

GR/SB

GR/SB

VO/SB

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y 1,0

Y/SB

W/SB

W

GR/SB

R/BL 1,5

SB 1,5

GR/R

BN/OR

LBN

GR/R

SB 1,0

Y

BL/W

BL/GR

Y 1,0

GN

Y/SB

OR 1,0

R/W

R/BL 1,5

R/BL 1,5

BN 1,0

SB 1,5

SB 1,5

SB 1,5

Y/W

GR/Y

GN/SB

GN/W

BL/OR

GN/R

R 1,0

SB 1,0

R/BL

Y 1,0

R/BL 1,5

SB 2,5

R 2,5

CAN 2

Y/W

GR/Y

SB 2,5

R 2,5

R/BL 1,5

GR/SB

W

W/SB

R

W/SB

SB

W

P0012803

190 47701632 10-2010

1 Battery

2 Main switch

3 Starter motor

4 Alternator

5 Main relay

6 Aux stop







13 Sensor, camshaft

14 Sensor, flywheel



17 Relay preheating

18 Fuse, preheating


20 Preheater






26 EGR internal


28 Wastegate valve


Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


47701632 10-2010 191

P0012804

192


TAD1640-42GE, TAD1641-43VE

SB 1,0

R 1,0

BN/OR

GR/GN

SB

OR

GR/OR

OR/SB

GR/SB

GR/SB

VO/SB

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

W 1,5

Y/SB

W/SB

W

BL

R/BL 1,5

SB 1,5

BL/OR

BL/GN

GN/SB

GN/W

R 1,0

SB 1,0

BN/OR

GR/W

GN/R

LBN

GR/R

SB 1,0

Y

BL/W

BL/GR

CAN 2

R/BL 1,5

R/BL 1,5

Y/W

GR/Y

SB 1,5

SB 1,5

SB 1,5

R/Y

OR

CAN j1939

R/BL

SB 25

SB 2,5

R/BL

R/Y

R 2,5

R 25

R 2,5

CAN 2

Y/W

GR/Y

SB 2,5

R 2,5

R/BL 1,5

BL

W

W/SB

R

W/SB

SB

W

47701632 10-2010

1 Battery

2 Starter motor

3 Alternator

4 Main relay

5 Stop switch


7 Connector - engine interface



10 Connector diagnostic J1587

11 Connector - application tool


13 Sensor, camshaft

14 Sensor, flywheel



17 Pre-heater relay

18 Fuse

19 Fuse 10A

20 Pre-heater


22 Sensor, oil level





27 Aux stop

28 Jumper - removable


Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


47701632 10-2010 193


TAD1650-51GE Visco fan

0,75 R

0,75

R

0,75 GR/OR

1,0 SB

1,0 R

0,75 BN/OR

0,75 GR/GN

0,75 SB

0,75

OR

0,75 GN

0,75 BL

0,75

0,75

OR/SB

GR/SB

0,5 GR/W

0,75 OR/SB

1,0 Y

1,0 Y

1,0 Y

1,0 Y

1,0 Y

1,0 Y

1,0 Y

1,0 Y

1,0 Y

1,0 Y

1,0 Y

1,0 Y

1,0 BN

0,75

GN/SB

0,75

GN/W

0,75

0,75

BL/GN

BL/OR

0,75 GN/R

1,0 R

1,0 SB

1,0 Y

1,0 Y

1,0Y

1,0 Y

0,75 Y/SB

0,75 W/SB

0,75

W

0,75

BL

1,5 R/BL

1,5 SB

0,75

0,75

GR/R

BN/OR

1,0

0,75

Y

W

0,75 SB

0,75

Y

0,75

0,75

BL/W

BL/GR

0,75

GN

0,75 Y/SB

1,0

0,75

OR

R/W

1,5 R/BL

1,5 R/BL

1,0 BN

1,5 SB

1,5 SB

1,5 SB

0,75

Y/W

0,75 GR/Y

0,75 SB

0,75

R/BL

1,5 R/BL

R/BL 1,5

SB 2,5

R/W

Y/SB

R 2,5

BN 1,0

R/BL 1,0

OR 1,0

2,5 SB

2,5 R

P0014271

194

CAN 2

0,75

Y/W

0,75

GR/Y

2,5 SB

2,5 R

1,5 R/BL

0,75

BL

0,75 W

0,75 W/SB

0,75

0,75

R

W/SB

0,75 SB

0,75 W

0,75 R

47701632 10-2010

1 Battery

2 Main switch

3 Starter motor

4 Alternator

5 Main relay

6 Aux stop

7 Connector, engine interface (8-pin)



10 VODIA input (diagnosis conn., 6-pin)



13 Sensor, camshaft

14 Sensor, flywheel



17 Relay, preheating

18 Fuse, preheating

19 Main circuit breaker, 10 A

20 Preheater

21 Preheat connector (4-pin)


23 EGR internal





28 Wastegate valve

29 Visco elecric fan

30 WIF connector


Visco electric fan

A = Fan speed sensor supply

B = Clutch contol high

C = Clutch control low

D = Fan speed sensor ground

E = Fan speed output

F = Not connected

Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


47701632 10-2010 195


Wiring diagram CIU

30

14

27

SB 2,5

R 2,5

R/BL 1,5

28

22

37

12

W

W/SB

Y/W

11

30

GR/Y

GN/Y

2

3

29

GN/SB

GN/OR

R/W

R/GR

1

15

35

41

R/BN

R/Y

VO

P

16

10

13

33

21

26

BN

R/SB

GR/SB

LBN

20

40

34

W/BL

Y

BL/Y

LBN

9

25

W/BN

W/GN

39

36

7

38

BL/OR

P/SB

VO/W

24

17

19

8

GL

R/GN

OR

W/GL

Y/BL

2

P0014020

13

R

14

R

15

16

17

18

19

20

21

22

28

R

R

24

8

9

10

11

12

25

R

R

SB 1,5

1

R 1,5

R/BL 1,5

1 2 3 4 5 6 7 8

23

1 2 3 4 5 6 7 8

27

1 2 3 4 5 6 7 8

26

SB

R/SB

SB

SB

7

SB

-

RPM/M

+

3

R/SB

R/SB

SB

7

-

P

G

+

4

R/SB

SB

7

-

C

G

+

5

R/SB

7

-

C

G

+

6

SB

R/SB

1

2

3

29

196 47701632 10-2010

1 Key switch (15+)

2 RPM potentiometer

3 Tachometer (code 14)

4 Oil pressure, instrument

5 Oil temperature, instrument

6 Coolant temperature, instrument

7 Instrument illumination

8 Idling contact, two-way

9 1500 / 1800 rpm switch, two-way

10 Starter contact, spring biased

11 Stop switch, spring biased

12 Diagnosis contact, spring return

13 Alarm, low oil pressure

14 Alarm, high oil temperature

15 Alarm, high coolant temperature

16 Alarm, low coolant level

17 Fuel alarm

18 Diagnostic lamp

19 Engine overspeed indication (GE) Horn (VE)

20 Operation indicator

21 Pre-heating indication

22 Pre-heating contact

23 8-pin connector engine interface

24 Governor switch

25 Battery voltage alarm

26 Termination resistance 120 Ohm


28 Contact, engine protector disconnect

29 Easy Link connector block

30 Control Interface Unit (CIU)


Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


47701632 10-2010 197


Wiring diagram DCU

11

1

2

3

4

5

6

7

8

Y/W

GR/W

SB 2,5

R 2,5

R/BL 2,5

BL 2,5

W

W/SB

VO

D

C

U

1

2

R/Y

SB/Y

3

R/BL

4

Y

5

SB

6

GN/R

7

8

GN/Y

GN/SB

9

10

SB/VO

11

SB/GR

12

P0014021

SB/W

7

1

2

6

1

2

3

5

1

3

1 Stop contact

2 Start contact

3 1-pin connector

4 Horn, buzzer alarm

5 Easy Link connector

6 RPM-potentiometer

7 Indicator engine operation



10 Termination resistance 120 Ohm

11 Display Control unit (DCU)

1 2 3 4 5 6 7 8

8

4

1 2 3 4 5 6 7 8

9

1 2 3 4 5 6 7 8

10

Cable colors

BL = Blue

BN = Brown

GN = Green

GR = Gray

OR = Orange

LBL = Light blue

LBN = Light brown

P = Pink

R = Red

SB = Black

VO = Violet

W = White

Y = Yellow


2


198 47701632 10-2010

39-0 General

39-0 General

Index

MID 128

Caption

MID 128, PID 45 Inlet air heater status page 50

MID 128, PID 94 Fuel Delivery Pressure page 52

MID 128, PID 97 Water in fuel indicator page 55

MID 128, PID 98 Engine oil level page 57

MID 128, PID 100 Engine oil pressure page 59

MID 128, PID 105 Intake manifold temperature page 62

MID 128, PID 106 Air inlet pressure page 64

MID 128, PID 107 Air filter pressure drop page 67

MID 128, PID 108 Barometric pressure page 70

MID 128, PID 110 Engine coolant temperature page 71

MID 128, PID 111 Coolant level page 74

MID 128, PID 153 Crankcase pressure page 76

MID 128, PID 158 ECU battery potential page 79

SPN

626

94

97

98

100

105

106

107

108

110

111

153

158

MID 128, PID 172 Inlet air temperature page 80

MID 128, PID 173 Exhaust gas temperature page 82

MID 128, PID 175 Engine oil temperature page 84

MID 128, PID 190 Engine speed page 87

MID 128, PPID 3 Starter Output page 88

MID 128 / 144, PPID 4 Starter input sensor page 90

MID 128, PPID 6 Key off input sensor page 91

MID 128, PPID 8 Piston Cooling Oil Pressure page 92

MID 128, PPID 19 Internal EGR Status page 94

MID 128, PPID 55 ECU temperature page 97

MID 128, PPID 98 Engine sync acknowledge page 98

520192 6.8/6.7

2791 5.5/-

-

608

-

-/-

MID 128 / 144, PPID 132 Throttle calibrated position page 99

608

MID 128, PPID 332 Thermostat page 101

2988

MID 128, SID 1/2/3/4/5/6 Injector # 1-6 page 103

MID 128, SID 21 Engine position page 107

651–656

636

2.8/-

-/-

7.1/7.6/-

2.5/-

MID 128, SID 22 Timing sensor, crank page 109

MID 128, SID 32, Wastegate output driver page 111

MID 128, SID 70 Air inlet heater driver #1 page 114

MID 128, SID 211 Sensor Supply Voltage #2 (+5V

DC) page 116

MID 128 / 144, SID 231 SAE J1939 data link page 117

MID 128, SID 232 5 V supply page 118

MID 128, SID 240 Program memory page 119

172

1184

175

190

-

677

520195

970

637

1188

-

729

639

620

639

7.9/-

-/-

3.7/5.8

-/2.6

4.6/-

4.7/5.2

4.8/- (EMS)

5.3/- (CIU)

2.4/-

-/-

-/-

9.3/-

6.5/- (EMS)

6.4/- (CIU)

9.3/-

9.9/-

Flashcode

Electrical fault / value fault

5.4/-

3.6/3.8

2.9/2.1

5.9/5.7

3.1/6.6

3.2/6.2

3.4/3.5

5.5/5.5

-/-

3.3/6.1

2.3/2.2

7.8/7.7

-/3.9 (EMS)

-/6.9 (CIU)

FMI

1, 3

3, 4, 5, 7

0, 4, 5

9

3, 4, 9

3, 4, 5

3, 4, 5, 7, 12

2, 3, 8

2, 3, 8

3, 4, 5

3, 4, 5

3, 4

2

3, 4

2, 7, 11, 14

3, 4, 5

1, 3, 5

0, 3

1, 5

1, 3, 5

0, 4, 5

0, 3, 5

1, 3, 5

2, 3, 4

0, 4, 5

1, 3

0, 3, 5

1

4, 5

0, 4, 5

0, 4, 5

0

3, 4, 5

3, 4

4

47701632 10-2010 199

39-0 General

MID 128, SID 250 SAE J1708/J1587 data link page 120

MID 128 / 144, SID 253 Calibration memory

EEPROM page 121

MID 128 / 144, SID 254 Controller 1 page 122

MID 128, PSID 201 Data link, MID144 page 123

608

630

9.2/-

9.9/- (EMS)

9.8/- (CIU)

629 9.9/- (EMS)

9.8/- (CIU)

639/1675 -/-

12

2, 12, 14

3, 8, 12

9

200 47701632 10-2010

Alphabetical index

About this Workshop manual................................ 2

Alternator fault tracing............................................. 46

Checking air inlet pressure sensor................... 139

Checking air inlet temperature sensor................... 148

Checking air pressure switch................................ 140

Checking camshaft sensor.................................... 165

Checking camshaft sensor wiring.......................... 164

Checking CAN bus cable...................................... 171

Checking coolant level switch............................... 144

Checking coolant temperature sensor................... 141

Checking crankcase pressure sensor................... 144

Checking exhaust gas temperature sensor........... 149

Checking flywheel sensor...................................... 167

Checking flywheel sensor wiring........................... 166

Checking fuel pressure sensor.............................. 128

Checking IEGR solenoid....................................... 158

Checking IEGR wiring........................................... 163

Checking inlet manifold temperature sensor......... 137

Checking negative cable, air filter pressure switch.................................................................... 153

Checking negative cable, air filter temperature switch.................................................................... 146

Checking negative cable, coldstart valve.............. 160

Checking negative cable, coolant level switch...... 143

Checking negative cable, coolant temperature switch.................................................................... 156

Checking negative cable, crankcase pressure sensor.................................................................... 174

Checking negative cable, exhaust gas temperature sensor.......................................................... 149

Checking negative cable, fuel sensor.................... 126

Checking negative cable, inlet manifold pressure/temperature sensor....................................... 135

Checking negative cable, oil pressure sensor....... 132

Checking negative cable, oil temperature switch.................................................................... 150

Checking negative cable, piston cooling oil temperature switch...................................................... 156

Checking negative cable, wastegate valve........... 168

Checking negative cable, water in fuel switch....... 130

Checking oil level sensor....................................... 131

Checking oil pressure sensor................................ 133

Checking oil temperature sensor........................... 152

Checking preheater relay...................................... 171

Checking signal cable voltage, inlet manifold

(pressure/)temperature sensor.............................. 134

Checking signal cable, air filter temperature switch.................................................................... 145

Checking signal cable, coolant temperature switch.................................................................... 155

Checking signal cable, crankcase pressure sensor.................................................................... 174

Checking signal cable, exhaust gas temperature sensor............................................................ 148

Checking signal cable, inlet manifold pressure sensor.................................................................... 138

Checking signal cable, oil pressure sensor........... 133

Checking signal cable, oil temperature switch...... 151

Checking starter motor relay................................. 153

Checking stop signal cable between ECU and

CIU/DCU............................................................... 154

Checking supply cable, air filter pressure switch... 139

Checking supply cable, coldstart valve................. 159

Checking supply cable, coolant level switch......... 143

Checking supply cable, crankcase pressure sensor.................................................................... 175

Checking supply cable, fuel sensor....................... 125

Checking supply cable, inlet manifold pressure sensor.................................................................... 138

Checking supply cable, oil pressure sensor.......... 132

Checking supply cable, piston cooling oil temperature switch...................................................... 157

Checking supply cable, wastegate valve............... 169

Checking supply cable, water in fuel switch.......... 129

Checking the CAN bus cable................................ 173

Checking the charging system................................ 45

Checking the IEGR coil......................................... 157

Checking the injector wiring.................................. 162

Checking the sensor cable for open circuit or shortcircuit............................................. 136, 142, 147

Checking the signal cable for interruption or shortcircuit............................................................. 127

Checking the starter motor voltage......................... 44

Checking the wastegate valve............................... 170

Checking the wiring............................................... 125

Checking water in fuel switch................................ 130

Component description........................................... 29

Component location................................................ 21

Design and Function............................................. 17

Electrical System..................................................... 6

Electrical Welding.................................................... 36

EMS 2 (Engine Management System).................... 17

Engine Control Unit (ECU), Replace....................... 37

Engine Protection Map.............................................. 8

Fault Codes............................................................ 50

Fault Tracing........................................................... 50

Fault tracing of cables and connectors.................... 40

General....................................................... 2, 17, 199

General advice........................................................ 49

Index..................................................................... 199

Joining electrical cables for connectors............. 42

Malfunctions.......................................................... 48

Manual fault tracing in bus cables........................... 47

MID 128 / 144, PPID 132 Throttle calibrated position.................................................................... 99

MID 128 / 144, PPID 4 Starter input sensor............ 90

MID 128 / 144, SID 231 SAE J1939 data link....... 117

MID 128 / 144, SID 253 Calibration memory

EEPROM............................................................... 121

MID 128 / 144, SID 254 Controller 1..................... 122

MID 128, PID 100 Engine oil pressure.................... 59

MID 128, PID 105 Intake manifold temperature...... 62

MID 128, PID 106 Air inlet pressure........................ 64

47701632 10-2010 201

MID 128, PID 107 Air filter pressure drop .............. 67

MID 128, PID 108 Barometric pressure.................. 70

MID 128, PID 110 Engine coolant temperature....... 71

MID 128, PID 111 Coolant level.............................. 74

MID 128, PID 153 Crankcase pressure................... 76

MID 128, PID 158 ECU battery potential................. 79

MID 128, PID 172 Inlet air temperature................... 80

MID 128, PID 173 Exhaust gas temperature........... 82

MID 128, PID 175 Engine oil temperature............... 84

MID 128, PID 190 Engine speed............................. 87

MID 128, PID 45 Inlet air heater status................... 50

MID 128, PID 94 Fuel Delivery Pressure................ 52

MID 128, PID 97 Water in fuel indicator.................. 55

MID 128, PID 98 Engine oil level............................. 57

MID 128, PPID 19 Internal EGR Status.................. 94

MID 128, PPID 3 Starter Output.............................. 88

MID 128, PPID 332 Thermostat............................ 101

MID 128, PPID 55 ECU temperature...................... 97

MID 128, PPID 6 Key off input sensor..................... 91

MID 128, PPID 8 Piston Cooling Oil Pressure........ 92

MID 128, PPID 98 Engine sync acknowledge......... 98

MID 128, PSID 201 Data link, MID144.................. 123

MID 128, SID 1/2/3/4/5/6 Injector # 1-6................. 103

MID 128, SID 21 Engine position.......................... 107

MID 128, SID 211 Sensor Supply Voltage #2

(+5V DC)............................................................... 116

MID 128, SID 22 Timing sensor, crank................. 109

MID 128, SID 232 5 V supply................................ 118

MID 128, SID 240 Program memory..................... 119

MID 128, SID 250 SAE J1708/J1587 data link...... 120

MID 128, SID 32, Wastegate output driver............ 111

MID 128, SID 70 Air inlet heater driver #1............. 114

No fault code........................................................ 124

Programming an empty control unit................... 39

Repair Instructions................................................ 36

Repair instructions..................................................... 3

Reprogramming a control unit................................. 38

Safety Instructions................................................ 11

Special Service Tools.............................................. 15

Specifications, Electrical............................................ 6

Technical Data......................................................... 6

Trimming the injector............................................. 161

Vodia logging throttle signal.............................. 175

Wiring Diagrams.................................................. 176

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AB Volvo Penta

Service Communication

Dept. 42200

SE-405 08 Göteborg

Sweden

Volvo Penta 9L, 12L, 13L, 16L Industrial Engines Workshop Manual

Assistant Bot

Workshop Manual

Group 30 Electrical system

I

5(0)

9L, 12L, 13L, 16L

Industrial Engines

Content

General Information

Specifications

Safety and Other Instructions

Special tools

General, Complete Vehicle Software

Cables and fuses

Miscellaneous

00-0 General

About this Workshop manual

Repair instructions

03-3 Specifications, Electrical

Electrical System

Technical Data

Engine Protection Map

05-1 Safety Instructions

Safety Information

08-2 Special Service Tools

30-0 General

Design and Function

EMS 2 (Engine Management

System)

Component location

Component description

Repair Instructions

Electrical Welding

Engine Control Unit (ECU), Replace

Reprogramming a control unit

Programming an empty control unit

Fault tracing of cables and connectors

Joining electrical cables for connectors

Checking the starter motor voltage

Checking the charging system

Alternator fault tracing

Manual fault tracing in bus cables

Malfunctions

General advice

30-2 Fault Tracing

Fault Codes

MID 128, PID 45 Inlet air heater status

MID 128, PID 94 Fuel Delivery

Pressure

MID 128, PID 97 Water in fuel indicator

MID 128, PID 98 Engine oil level

MID 128, PID 100 Engine oil pressure

MID 128, PID 105 Intake manifold temperature

MID 128, PID 106 Air inlet pressure

MID 128, PID 107 Air filter pressure drop

MID 128, PID 108 Barometric pressure

MID 128, PID 110 Engine coolant temperature

MID 128, PID 111 Coolant level

MID 128, PID 153 Crankcase pressure

MID 128, PID 158 ECU battery potential

MID 128, PID 172 Inlet air temperature

MID 128, PID 173 Exhaust gas temperature

MID 128, PID 175 Engine oil temperature

MID 128, PID 190 Engine speed

MID 128, PPID 3 Starter Output

MID 128 / 144, PPID 4 Starter input sensor

MID 128, PPID 6 Key off input sensor

MID 128, PPID 8 Piston Cooling Oil

Pressure

MID 128, PPID 19 Internal EGR

Status

MID 128, PPID 55 ECU temperature

MID 128, PPID 98 Engine sync acknowledge

MID 128 / 144, PPID 132 Throttle calibrated position

MID 128, PPID 332 Thermostat

MID 128, SID 1/2/3/4/5/6 Injector # 1-6

MID 128, SID 21 Engine position

MID 128, SID 22 Timing sensor, crank

MID 128, SID 32, Wastegate output driver