Workshop Manual: Group 30 Electrical System I

Workshop Manual I
Group 30 Electrical system 5(0)
TAD734GE, TAD550-551GE, TAD750-751GE,

TAD752-754GE, TAD560-561VE, TAD650VE,
TAD660VE, TAD750VE, TAD760VE, TAD761-765VE
Content
General Information
00-0 General ................................................................................................ 2
Specifications
03-3 Specifications, Electrical ................................................................... 5
Electrical System ........................................................................................ 5
Engine Protection Map ............................................................................... 7
Safety and Other Instructions

05-1 Safety Instructions ........................................................................... 10
Special tools
08-2 Special Service Tools ....................................................................... 14
General, Complete Vehicle Software

30-0 General .............................................................................................. 16
Design and Function ................................................................................ 16
30-2 Fault Tracing ..................................................................................... 43
General ....................................................................................................... 43
Fault Codes ............................................................................................... 45
Measurements ......................................................................................... 115
VODIA Log Parameters .......................................................................... 147
Cables and fuses

37-0 Wiring Diagrams ............................................................................. 148
Miscellaneous
39-0 General ............................................................................................ 163
Alphabetical index .................................................................................. 165
References to Service Bulletins ............................................................ 167
47702487 11-2012 © AB VOLVO PENTA 1

00-0 General
Concerned engines
This Workshop Manual concerns the following engine models:
• TAD550GE • TAD752GE • TAD560VE • TAD750VE • TAD763VE

• TAD751GE • TAD734GE • TAD660VE • TAD762VE
About this Workshop manual

General information Certified engines
This Service Manual contains technical data, descrip- When carrying out service and repair on emis-
tions and maintenance and repair instructions for sion-certified engines, it is important to be aware
standard model Volvo Penta products. A list of these of the following:
products may be found in the section Specifica-
tions. Certification means that an engine type has been
inspected and approved by the relevant authority.
The product designation and the serial number and The engine manufacturer guarantees that all engines
specification is indicated on the engine decal or type of the same type are manufactured to correspond to
plate. This information must be included in all corre- the certified engine.
spondence regarding the product. This places special demands on service and repair
work, namely:
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified person- • Maintenance and service intervals recom-
nel. It is assumed that any person using the Service mended by Volvo Penta must be complied with.
Manual has a fundamental knowledge of the product • Only spare parts approved by Volvo Penta may
and is able to carry out mechanical and electrical be used.
work to trade standard.
• Service on injection pumps, pump settings and
Volvo Penta continually develops its products; we injectors must always be carried out by an
therefore reserve the right to make changes. All infor- authorized Volvo Penta workshop.
mation in this manual is based on product data which
• The engine must not be converted or modified,
was available up to the date on which the manual was
except with accessories and service kits which
printed. New working methods and significant
Volvo Penta has approved for the engine.
changes introduced to the product after this date are
communicated in the form of Service bulletins. • No changes to the exhaust pipe and engine air
inlet duct installations may be made.
Spare Parts
• No warranty seals (where present on the prod-
Spare parts for the electrical and fuel systems are uct) may be broken by unauthorized persons.
subject to various national safety standards. Volvo
Penta Original Spare Parts meet these standards. No The general instructions in the Operator's Manual
damage of any kind caused by the use of spare parts concerning operation, service and maintenance
not approved by Volvo Penta will be compensated by apply.
any warranty undertaking.
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.
2 47702487 11-2012 © AB VOLVO PENTA

00-0 General
Repair instructions
Introduction Our mutual responsibility
The working methods described in this manual are Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the tech-
mounted in a holding fixture. Maintenance work is nical specification may dramatically increase the
often carried out on site, in which case – if nothing environmental impact of an otherwise reliable sys-
else is indicated – using the same working methods tem. It is therefore critical that the stated wear toler-
as the workshop. ances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and
For significance, refer to Safety Information . maintenance schedule must be followed.
! DANGER! Some systems, e.g. fuel systems, often require spe-
cial expertise and test equipment. A number of com-
! WARNING! ponents are factory-sealed, for among other things
environmental reasons. Warranty-sealed compo-
! CAUTION!
nents may not be worked on without authorization to
perform such work.
IMPORTANT!, NOTICE!
are by no means comprehensive since not everything Remember that most chemical products, incorrectly
can be foreseen as service work is carried out in the used, are harmful to the environment. Volvo Penta
most varied of circumstances. We call attention to recommends the use of biodegradable degreasers
risks that may occur due to incorrect handling during whenever components are cleaned, unless otherwise
work in a well-equipped workshop using working specified in the Service Manual. When working out-
methods and tools tried and tested by us. doors, take especial care to ensure that oils and wash
residues etc. are correctly properly for destruction.
The service manual describes work operations car-
ried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Spe-
Tightening torques
cial Tools are designed to ensure the safest and most Tightening torques for vital fasteners that must be
rational working methods possible. It is therefore the applied using a torque wrench are indicated in the
responsibility of anyone using tools or working meth- Service Manual, chapter Tightening torques and in
ods other than those we recommend to ensure that the Manual's work descriptions. All torque indications
no risk of personal injury or mechanical damage is apply to clean threads, bolt heads and mating faces.
present, or that malfunction can result. Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
In some cases, special safety regulations and user required for fasteners, the correct type will be noted
instructions may be in force for the tools and chemi- in the job description.
cals mentioned in the Service Manual. These regu-
lations must always be followed, and no special
Torque, angle tightening
instructions regarding this are to be found in the Serv-
ice Manual. When torque/angle tightening, the fastener is tight-
ened to a specified torque, and tightening then con-
By taking these basic precautions and using common tinues through a pre-determined angle.
sense it will be possible to guard against most ele-
ments of risk. A clean workplace and a clean product Example: For 90° angle tightening, the fastener is
will eliminate many risks of personal injury and mal- turned a further 1/4 turn in one sequence, after the
function. specified tightening torque has been achieved.
Above all, when working on fuel systems, hydraulic

systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost impor-
tance that dirt and foreign objects are kept away, as
malfunctions or shortened service intervals may oth-
erwise result.
47702487 11-2012 © AB VOLVO PENTA 3

00-0 General
Lock nuts Anaerobic agents.

These agents cure (harden) in the absence of air.
Removed locknuts may not be re-used; they must be These preparations are used when two solid compo-
replaced by new ones, as locking properties are nents, e.g. two cast components, are fitted together
impaired or lost with re-use. without a gasket. Common uses are also to lock and
In the case of lock nuts with plastic inserts the tight- seal plugs, stud threads, taps, oil pressure monitors
ening torque indicated must be reduced if the nut has etc.
the same nut height as a standard, all-metal hexag-
onal nut. Hardened anaerobic preparations are glassy and for
Reduce the torque by 25% for bolt sizes of 8 mm or this reason, the preparations are colored to make
larger. them visible. Hardened anaerobic preparations are
In the case of lock nuts with plastic inserts with a high highly resistant to solvents, and old compound can-
nut-height (where the all-metal thread is as high as a not be removed. On re-assembly, it is important to
standard hexagonal nut), the indicated torque carefully degrease and wipe dry components first,
applies. before applying new sealant in accordance with the
instructions.
Strength classes
Safety regulations for fluorocarbon
Nuts and bolts are subdivided into different strength
classes. The classification is shown by a marking on rubber
the bolt head. Markings of a higher number indicate Fluorocarbon rubber is a common material in sealing
stronger material. For example, a bolt marked 10-9 is rings for shafts, and in O-rings, for example.
stronger than one marked 8-8.
When fluorocarbon rubber is exposed to high tem-
For this reason, it is important that when bolts are peratures (above 300°C/572°F), hydrofluoric acid
removed they are returned to their original locations can form. This is highly corrosive. Contact with the
on re-assembly. When replacing bolts check the skin can result in severe chemical burns. Splashes in
applicable Spare parts catalogue to ensure the cor- your eyes can result in chemical wounds. If you
rect bolt is used. breathe in the fumes, your lungs can be permanently
damaged.
Sealing compounds etc.
To ensure service work is correctly carried out it is WARNING!
important that the correct type of sealants and locking Seals must never be cut with a torch, or be burnt
fluids are used on joints where such are required. afterwards in an uncontrolled manner. Risk for
poisonous gases.
In each service manual section concerned, the seal-
ants used in product manufacture are indicated. The
same sealants, or sealants with equivalent proper- WARNING!
ties, must be used for maintenance work. Always use chloroprene rubber gloves (gloves for
chemicals handling) and goggles. Handle the
Make sure that mating surfaces are dry and free from removed seal in the same way as corrosive acid. All
oil, grease, paint and anti-corrosion agent before residue, including ash, can be highly corrosive. Never
applying sealant or locking fluid. Always follow the use compressed air to blow clean.
manufacturer's instructions regarding applicable Put the remains in a plastic container, seal it and
temperatures, hardening times and such. apply a warning label. Wash the gloves under running
Two basic types of compound are used: water before removing them.
RTV preparations (Room Temperature Vulcaniz- The following seals are most probably made from flu-
ing). orocarbon rubber:
Used most often together with gaskets, e.g. sealing Seal rings for the crankshaft, camshaft, idler shafts.
gasket joints, or are brushed on gaskets. RTV seal-
ants are completely visible when the part has been O-rings, regardless of where they are installed. O-
removed. Old RTV sealant must be removed before rings for cylinder liner sealing are almost always
the component is sealed again. Use denatured alco- made of fluorocarbon rubber.
hol.
Please note that seals which have not been
exposed to high temperature can be handled nor-
mally.
4 47702487 11-2012 © AB VOLVO PENTA

03-3 Specifications, Electrical
Electrical System
Technical Data
Switch, Water in Fuel
Voltage 24 V
Connector 2–pin
Contact type Closes when water is detected
Sensor, Fuel Pressure

Voltage 5V
Connector 3–pin
Working pressure range 0–700 kPa (0-7 bar) (0–101.5 PSI)
Pressure signal 0.5–4.5 V
Working temperature range -40 °C to +140 °C (-40 °F to +284 °F)
Type Linear
Max tightening torque 30 ±5 Nm (22 ±3.7 lbf.ft.)
Speed sensor, Camshaft / Speed sensor, Crankshaft

Connector 3–pin
Type Inductive sensor
Max. tightening torque 8 ±2 Nm (5.9 ±1.48 lbf.ft.)
Sensor, Oil pressure

Voltage 5V
Connector 3–pin
Working pressure range 0–700 kPa (0-7 bar) (0–101.5 PSI)
Type Linear
Max tightening tourque 30 ±5 Nm (22 ±3.7 lbf.ft.)
Sensor, Rail pressure

Voltage 5V
Connector 3–pin
Working pressure range 0–180 MPa (0-1800 bar) (0–26110 PSI)
Type Linear
Max tightening tourque 70 Nm (51.6 lbf.ft.)
Combination sensor, Air inlet pressure / Inlet manifold temperature

Voltage 5V
Connector 4–pin
47702487 11-2012 © AB VOLVO PENTA 5

Working pressure range 50–400 kPa (0.5-4 bar) (7.3–58.0 PSI)

Type Linear/NTC
Sensor, Coolant temperature

Voltage 5V
Connector 2–pin
Type NTC
Max. tightening torque 25 Nm (18.4 lbf.ft.)
Switch, Coolant Level

Connector 2–pin
Contact type (black coolant level switch) Closing with low coolant level
Contact type (grey coolant level switch) Opens with low coolant level
Alternator
Voltage 28 V
Connector 2–pin
Capacity 80 A at 28 V
Starter motor
Voltage 24 V
Connector 1 pol
Capacity 5.5 kW
6 47702487 11-2012 © AB VOLVO PENTA

Engine Protection Map

TAD650/660/750/760VE
Derate to engine protection map

Parameter “Yellow “Red 0% 50 % 70 % 100 % Forced to Forced
lamp” lamp” idle after shut-
5 sec. down
after 15
sec.
High coolant 98 °C 101 °C 101 °C - - 106 °C >106 °C >106 °C
temperature (208.4 °F) (213.8 °F) (213.8 °F) (222.8 °F) (222.8 °F) (222.8 °F)
High boost 80 °C 83 °C 83 °C .- - 90 °C >90 °C >90 °C
temperature (176.0 °F) (181.4 °F) (181.4 °F) (194.0 °F) (194.0 °F) (194.0 °F)
High boost 340 kPa 350 kPa - 350 kPa - - >355 kPa >355 kPa
pressure (49.3 PSI) (50.8 PSI) (50.8 PSI) (51.5 PSI) (51.5 PSI)
Low oil pres- Limit 20 kPa - - 20 kPa - 25 kPa 25 kPa
sure (2.9 PSI) (2.9 PSI) (3.6 PSI) (3.6 PSI)
< Limit < Limit < Limit < Limit
Y 1500
1000
500
A
0
0 500 1000 1500 2000 2500 3000 3500 X
P0015455
Oil pressure limit A Engine protection

kPa X Torque, Nm
300 Y Engine speed, rpm
250
200
150
100
50
0
0 500 1000 1500 2000 2500 kPa Pressure
rpm rpm Engine speed
P0015456
47702487 11-2012 © AB VOLVO PENTA 7

TAD734GE
Parameter “Yellow lamp” “Red lamp” Forced shutdown

High coolant temperature 98 °C 106 °C >106 °C
(208.4 °F) (222.8 °F) (222.8 °F)
High boost temperature 80 °C 90 °C >90 °C
(176.0 °F) (194.0 °F) (194.0 °F)
High boost pressure 340 kPa 355 kPa >355 kPa
(49.3 PSI) (51.5 PSI) (51.5 PSI)
Low coolant level - switch switch
Low oil pressure Limit 25 kPa (3.6 PSI) < Limit 25 kPa (3.6 PSI) < Limit
Oil pressure limit

kPa
300
250
200
150
100
50
0 kPa Pressure
0 500 1000 1500 2000 2500 rpm Engine speed
rpm
P0015456
TAD550-551GE, 750-751GE, 752-754GE
Parameter Unit Warning level Alarm level Engine protection

Default setting
Yellow lamp Red lamp Level Action
Oil temperature °C (°F) 125 (257) 130 (266) 130 (266) Shut down
Oil pressure Low idle kPa (psi) 90 (1305) 80 (1160) 80 (1160) Shut down
1500 rpm kPa 200 (2901) 170 (2466) 170 (2466) Shut down
1800 rpm kPa 230 (3336) 200 (2901) 200 (2901) Shut down
Coolant temperature °C TAD550-751GE: TAD550-751GE: TAD550-751GE: Shut down
105 (221) 110 (230) 110 (230)
TAD752-754GE: TAD752-754GE: TAD752-754GE:

109 (228.2) 114 (237.2) 114 (237.2)
Coolant level On Low level Shut down
Altitude, above sea m Automatic derating
Charge air temperature °C 75 (167) 80 (176) 80 (176) Shut down
Charge air pressure kPa TAD550-751GE: TAD550-751GE: TAD550-751GE: Shut down
310 (4496) 320 (4641) 320 (4641)
TAD752-754GE: TAD752-754GE: TAD752-754GE:

340 (4931) 350 (5076) 350 (5076)
Engine Speed rpm 115 % of rated
speed
8 47702487 11-2012 © AB VOLVO PENTA

TAD560-56VE, TAD761-765VE
Parameter Warning level Alarm level Engine protection

Parameter for stationary Warning Alarm Action.
Default / Alternative
Oil Pressure Low idle 90 kPa (13.1 psi) 65 kPa (9.4 psi) 65 kPa (9.4 psi) Shut down. ON/
OFF(1)
Rated speed 250 kPa (36.3 psi) 225 kPa (32.6 psi) 225 kPa (32.6 psi) Shut down.
ON/OFF
Coolant Temperature 108° C (226.4° F) 110° C (230° F) 110° C (230° F) Shut down.
Coolant Level NA Low level Shut down. ON/OFF(1)
Fuel feed pressure Low idle 450 kPa (65.3 psi) NA NA
Rated speed 380 kPa (55.1 psi) NA NA
Water in Fuel High level NA NA
Intake manifold temperature 75° C (167° F) 80° C (176° F) 80° C (176° F) Shut down.
ON/OFF(1)
Air inlet pressure 380 kPa (55.1 psi) 390 kPa (56.6 psi) 390 kPa (56.6 psi) Shut down.
ON/OFF
Engine Speed 120 % NA NA
Parameter Engine protection

Parameter for mobile (2) 0 % derate 100 % derate Shut down value
Coolant Temperature 110° C (230° F) 111° C (231.8° F) NA
Coolant Level NA NA NA
Oil Pressure Low idle NA NA 65 kPa (9.4 psi)
Rated speed NA NA 225 kPa (32.6 psi)
Fuel feed pressure Low idle NA NA NA
Rated speed NA NA NA
Water in Fuel NA NA NA
Intake manifold temperature 80° C (176° F) 81° C (177.8° F) NA
Air inlet pressure 390 kPa (56.6 psi) 390 kPa (56.6 psi) NA
Engine Speed NA NA NA
SCR protection temperature 550° C (1022° F) >550° C (>1022° F) NA
1. OFF: Disables the function, i.e. no shut down.

2. For warning and alarm levels, see Parameter for stationary above.
47702487 11-2012 © AB VOLVO PENTA 9

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.
10 47702487 11-2012 © AB VOLVO PENTA

Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply to the engine at the main switch ! engine is hot. Steam or hot coolant can spray
(switches) and lock it (them) in the off position out and system pressure will be lost. Open the
before starting work. Post a warning notice at filler cap slowly, and release the pressure in the
the main circuit breaker. 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.
As a rule, all service operations must be carried Hot oil can cause burns. Avoid skin contact with
! out with the engine stopped. However, some ! hot oil. Ensure that the lubrication system is not
work, such as adjustments, will require the under pressure before any work is begun.
engine to be running. Approaching an engine Never start or operate the engine with the oil
which is running is a safety risk. Bear in mind filler cap removed, because of the risk of oil
that loose clothing or long hair can fasten in ejection.
rotating parts and cause serious personal
injury.
Be aware of hot surfaces (exhaust pipes, tur- Never start the engine without installing the air
! bos, charge air pipes, starting heaters etc.) and ! filter. The rotating compressor turbine in the tur-
hot fluids in pipes and hoses on an engine that bocharger can cause severe injury. Foreign
is running or has just stopped. objects entering the intake ducts can also cause
If work is done adjacent to a running engine, a mechanical damage. Install all protective cov-
careless movement or a dropped tool may in the ers before the engine is started.
worst case lead to personal injury.
Ensure that the warning symbols or information Only start the engine in a well-ventilated space.
! decals on the product are always clearly visible. ! When running in a confined space, exhaust
Replace decals which have been damaged or fumes and crankcase gases must be led away
painted over. from the engine bay or workshop area.
Avoid getting oil on your skin! Protracted or The majority of chemicals e.g. engine and trans-
! repeated exposure to oil can cause skin to ! mission oils, glycol, gasoline, and diesel oil,
become dry. Irritation, dryness, eczema and together with chemicals for workshop use such
other skin problems may then result. From a as degreasing agents, paints and solvents, are
health standpoint, used oil is more dangerous injurious to health. Carefully read the instruc-
than new. Use protective gloves and avoid oil- tions on the product packaging! Always follow a
soaked clothes and rags. Wash regularly, espe- product's safety directions, e.g. use of protec-
cially before eating. Use suitable barrier creams tive mask, glasses, gloves etc. Ensure that
to counteract drying out of the skin and to aid other personnel are not exposed to substances
dirt removal. that are injurious to health. Ensure good venti-
lation. Handle used and leftover chemicals in
the prescribed manner.
Stop the engine and turn off the electrical supply Clutch adjustments must be carried out with the
! at the main switch(es) before carrying out work ! engine stopped.
on the electrical system.
47702487 11-2012 © AB VOLVO PENTA 11

Always use protective glasses or goggles when Never start the engine with the valve cover
! carrying out work where a risk of splinters, ! removed. There is a risk of personal injury.
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 Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. Marine engines: Close the sea cock / cooling
water inlet valve before work on the cooling sys-
tem is begun.
All fuels, as well as many chemicals, are flam- Make sure that oil, fuel-soaked rags, and used
! mable. Do not allow open flames or sparks in ! fuel and oil filters are stored in a safe manner.
their vicinity. Gasoline, some thinners, and Rags soaked in oil can spontaneously ignite
hydrogen gas from batteries are extremely under certain circumstances. Used fuel and oil
flammable and explosive when mixed with air in filters are environmentally hazardous waste
the correct proportions. No Smoking! Ensure and must be handed to an approved waste
that the work area is well ventilated and take the management facility for destruction, as must
necessary safety precautions before welding or any used lubrication oil, contaminated fuel,
grinding work is begun. Always ensure that paint residue, solvents, degreasers and wash
there are fire extinguishers close at hand in the residue.
work area.
Batteries must never be exposed to open Never work alone when removing heavy com-
! flames or electric sparks. Never smoke in the ! ponents, even when using lifting devices such
vicinity of the batteries; they generate hydrogen as locking tackle lifts. When using a lifting
gas when charged, which is explosive when device, two people are usually required to do
mixed with air. This gas is easily ignited and the work - one to take care of the lifting device
highly explosive. A spark, which can be caused and the other to ensure that components are
by incorrect battery connection, is sufficient to lifted clear and not damaged during the lifting
cause a battery to explode and cause damage. operations.
Do not touch the connections during start

attempts. Sparking hazard! Do not lean over
batteries.
Never transpose the positive (+) and negative The existing lugs on the engine should be used
! (-) battery posts when installing batteries. Such ! for lifting. Always check that the lifting equip-
a transposition can result in serious damage to ment used is in good condition and has the load
electrical equipment. Refer to the wiring dia- capacity to lift the engine (engine weight includ-
gram. ing gearbox or extra equipment). For safe han-
Always use protective goggles when charging dling and to avoid damaging components fitted
and handling the batteries. Battery electrolyte to the top of the engine, the engine must be
contains sulfuric acid which is highly corrosive. lifted with a correctly adjusted lifting boom. All
Should the battery electrolyte come into contact chains or wires must run parallel to each other
with unprotected skin, wash it off immediately and as perpendicular to the engine as possible.
using soap and copious amounts of water. If you If other equipment attached to the engine has
get battery acid in your eyes, flush at once with altered its center of gravity, special lifting devi-
copious amounts of water and seek medical ces may be needed to obtain the correct bal-
assistance immediately. ance for safe handling. Never perform any work
on an engine that is only suspended from the
lifting equipment.
12 47702487 11-2012 © AB VOLVO PENTA

The components in the electrical and fuel sys- Exercise extreme caution when leak-detecting
! tems on Volvo Penta products are designed and ! on the fuel system and testing the fuel injector
manufactured to minimize the risk of fire and nozzles. Use eye protection. The jet from a fuel
explosion. The engine must not be run in areas nozzle has very high pressure and great pene-
where there are explosive materials. tration power. Fuel can force its way deep into
body tissue and cause severe injury. There is a
risk of blood poisoning (septicemia).
Only use fuels and lubricating oils recom- Never use a high-pressure washer for cleaning
! mended by Volvo Penta. Refer to the Operator's ! the engine.
Manual for the product in question. Use of fuels Pay attention to the following when using a high-
that are of a lower grade may damage the pressure washer on components other than the
engine, the injection pump and the injectors. On actual engine: Never direct the water jet at
a diesel engine, low grade fuel can cause the seals, rubber hoses or electrical components.
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 straight-

! ened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.
47702487 11-2012 © AB VOLVO PENTA 13

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.
8856
75 p0013275
P0008793
5
4
3
2
1
P0006701
885675 Break-out cable 9990014 Break-out cable 9990136 Break-out cable

Adapter cable for sensor test. Adapter cable EMS2. Adapter cable for relay test.
p0005128
9998482 Measuring tool 9998699 Break-out box 88890016 Break-out cable

Gauge for connector on control Used with 9990014 Break-out For use with 9998699 Break-
unit. cable. out box.
VODIA
p0005125
p0008375
88820047 VODIA, diagnostic 88890058 Pliers 88890074 Multimeter

tool Used for measurements.
Complete tool.
14 47702487 11-2012 © AB VOLVO PENTA

Other Special Equipment
LVO
52
VO
200
888
21346021 Cable 88820052 VODIA, diagnostic
High speed cable with connec- tool (interface)
tor. Used with docking station VORP docking station. Used
(88820052) on the engine com- with 88820047 VODIA, diag-
munication connector. nostic tool.
47702487 11-2012 © AB VOLVO PENTA 15

30-0 General
30-0 General
Design and Function

EMS 2 (Engine Management
System)
General Information
EMS 2 is an electronic system with CAN communica-
tion (Controller Area Network) for diesel engine con-
trol. 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 communi-
cations interface consisting of a CAN link and a serial
link.
CAN - Controller Area Network

The J1939 CAN link is responsible after all communi-
cation between the engine control unit (EMS 2) and a
communication interface (such as CIU/DCU), except
for diagnostics. Diagnostics are managed by the so-
called 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 trans-
missions.
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. How-
ever, 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).
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 infor-

mation for, among other things, the flashing code. The
P0002060
VODIA diagnosis tool also uses the J1708/J1587 link
to communicate with the system.
16 47702487 11-2012 © AB VOLVO PENTA

30-0 General
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
P0002932 - Start, stop, speed control, pre-heating etc.
Monitoring
- Engine speed, air inlet pressure, inlet manifold tem-
perature, coolant temperature, oil pressure, oil tem-
perature, engine hours, battery voltage, instantane-
ous 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.
Fuel control
The amount of fuel injected into the engine and the
injection advance are fully electronically controlled, via
fuel valves in the injectors, once the control unit has
analyzed the engine’s fuel requirements.
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 monitors and reads the injectors to

ensure that the correct volume of fuel is injected into
each cylinder, and it calculates and set the injection
advance. Control is mainly done with the help of the
speed sensors, fuel pressure sensor and the combined
sensor for air inlet pressure/inlet manifold temperature.
The control unit controls the injectors via a signal to the

electromagnetically operated fuel valve in each injec-
tor, which can be opened and closed.
47702487 11-2012 © AB VOLVO PENTA 17

30-0 General
Calculation of fuel quantity

The quantity of fuel to be injected into the cylinder is
calculated by the control unit. The calculation deter-
mines 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
• Air inlet 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 lim-
its 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 pro-
tect 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 flash-
ing 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 work-
shops.
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 trac-
ing.
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30-0 General
Component location
1 Speed sensor, Cam- TAD650, 660, 750, 760 VE
shaft 4
3 5
2 Connection, EMS 2 6
3 Solenoid controlled
proportional valve,
high pressure pump –
fuel (MPROP)
4 Fuel Pressure 2
5 Fuel pressure in com-

man rail
6 Glow plugs, one for
each injector
7 Oil pressure sensor
8 Air inlet pressure and
1
temperature 7
9 Solenoid valve, EGR
10 Coolant Temperature
11 Speed sensor, Crank-
shaft
12 Water in Fuel (not P0015429
shown, mounted on
primary fuel filter).
NOTICE! Location can dif-

fer, depending on engine 8
model.
10
11
P0015430
47702487 11-2012 © AB VOLVO PENTA 19

30-0 General
TAD734GE
2
1
1 Solenoid controlled
proportional valve,
high pressure pump –
fuel (MPROP)
2 Coolant temperature
sensor
3 Water in fuel switch
(mounted on primary
fuel filter)
4 Air inlet pressure and
temperature sensor
5 Preheater, intake
manifold
6 Fuel pressure in com- 3
man rail
P0015431
7 Fuel pressure sensor
8 Oil pressure sensor 5
4
9 Main relay 6
10 Speed sensor, Crank-

shaft
11 Speed sensor, Cam-
shaft
NOTICE! Coolant level

switch is located in the
7
10
11
8
P0015433 P0015432
20 47702487 11-2012 © AB VOLVO PENTA

30-0 General
TAD550/551GE
10
2
8 9
11
4
P0015181
7
1 Coolant level sensor, in expansion tank 7 Water in fuel sensor

2 Charge air temp and pressure sensor 8 Fuel pressure sensor, (low press)
3 Air filter indicator 9 Fuel pressure sensor, (high press)
4 Crank sensor (RPM) 10 Coolant temperature sensor
5 Fuse 11 Camshaft position sensor
47702487 11-2012 © AB VOLVO PENTA 21

30-0 General
TAD750/751GE
10
2
8 9
11
P0015182
7
1 Coolant level sensor, in expansion tank 7 Water in fuel sensor

2 Charge air temp and pressure sensor 8 Fuel pressure sensor, (low press)
3 Air filter indicator 9 Fuel pressure sensor, (high press)
4 Crank sensor (RPM) 10 Coolant temperature sensor
5 Fuse 11 Camshaft position sensor
22 47702487 11-2012 © AB VOLVO PENTA

30-0 General
TAD752/753/754GE
2
11 3
9 10
6
12
P0015185
7
1 Coolant level sensor, in expansion tank 7 Oil pressure sensor

2 Charge air temp and pressure sensor 8 Water in fuel sensor
3 Air filter indicator 9 Fuel pressure sensor, (low press)
4 Crank sensor (RPM) 10 Fuel pressure sensor, (high press)
5 Fuse 11 Coolant temperature sensor
6 AUX stop 12 Camshaft position sensor
47702487 11-2012 © AB VOLVO PENTA 23

30-0 General
TAD560/561VE
1a 1b 2 13
10
14
11 4 12 9
5
8
7 6
P0015183
1a Coolant level sensor, in expansion tank 8 Fuel pressure sensor, (low press)
1b Connection point for coolant level sensor 9 Coolant temperature sensor
2 Charge air temperature and pressure sensor 10 Camshaft position sensor
3 Crank sensor (RPM) 11 Fuse, eats
4 Fuse, engine 12 Fuel pressure, (high pressure in rail)
5 Aux stop 13 Ambient air temperature sensor
6 Oil pressure sensor 14 Fuse, pre-heater
7 Water in fuel sensor
24 47702487 11-2012 © AB VOLVO PENTA

30-0 General
TAD761-765VE
1a 1b 2 13
10
14
11 4 12 9
5
8
P0015184
7 6
1a Coolant level sensor, in expansion tank 8 Fuel pressure sensor, (low press)
1b Connection point for coolant level sensor 9 Coolant temperature sensor
2 Charge air temp and pressure sensor 10 Camshaft position sensor
3 Crank sensor (RPM) 11 Fuse, eats
4 Fuse, engine 12 Fuel pressure, (high pressure in rail)
5 Aux stop 13 Ambient air temperature sensor
6 Oil pressure sensor 14 Fuse pre-heater
7 Water in fuel sensor
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30-0 General
Component description
Starter motor
The starter motor is installed in the flywheel housing,
on the left-hand side of the engine. The starter motor
relay is "positive connected", which means that the
relay is connected to battery voltage.
Alternator
The alternator is belt driven and mounted on the front
of the engine, on the right.
P0015434
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30-0 General
Injectors
The injectors are installed on the cylinder head.
The amount of fuel injected and injection duration is

controlled by the engine control unit, via electromag-
netically controlled fuel valves in the injectors. This
means that the engine always receives the correct vol-
ume of fuel in all operating conditions, which offers
lower fuel consumption, minimal exhaust emissions
etc.
P0015435
Speed sensor, crankshaft

The position sensor is located in the upper timing gear
cover. The camshaft position sensor is of the induc-
tive-sensor 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.
TAD650/660/750/760VE,
TAD550/551/750/751GE
P0015436
TAD734GE, TAD752/753/754GE,
P0008694 TAD560-561VE, TAD761-765VE
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30-0 General
Speed sensor, camshaft (camshaft

position)
The camshaft sensor is an inductive sensor. When the
camshaft rotates impulses are created in the sensor
via a tooth wheel installed on the camshaft. The tooth
has seven teeth, one for each cylinder and one to
TAD650/660/750/760VE, determine when cylinder one is to be injected. The
TAD550/551/750/751GE impulses create a pulse signal in the sensor that the
engine control unit (EMS 2) uses to calculate when a
P0015436
cylinder is in turn for injection.
TAD734GE, TAD752/753/754GE,
TAD560-561VE, TAD761-765VE
P0015437
Air inlet pressure / inlet manifold

temperature sensor
The air inlet pressure and the inlet manifold tempera-
ture are measured by a combined sensor located on
the inlet manifold on the left of the engine.
The sensor is supplied by a 5 Volt reference voltage

from the engine control module.
The air inlet pressure sensor measures the absolute

pressure, which is the sum of the air inlet pressure and
atmospheric pressure (300 kPa thus corresponds to a
air inlet pressure of 200 kPa when atmospheric pres-
sure is 100 kPa).
The pressure signal is a voltage signal which is pro-

portional to absolute pressure.
The inlet manifold temperature sensor consists of a

non-linear resistor, whose resistance varies with inlet
manifold temperature. The resistance falls as the tem-
perature rises.
Sensor, oil pressure, engine

Oil pressure is measured by a sensor installed in the
engine block on the right side of the engine.
The sensor measures pressure in the main oil gallery,

and is supplied by a 5 Volt reference voltage from the
P0015438 engine control module.
The pressure signal is a voltage signal which is pro-

portional to the lubrication oil pressure.
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30-0 General
IEGR (only VE engines)

The IEGR valve is a 2-way solenoid valve controlled
by the engine control unit. The IEGR solenoid controls
a oil pressure that effects a control valve which activate
the exhaust gas recirculation function.
P0015439
Coolant temperature sensor

The sensor is located on the cylinder head, at the rear
end of the engine.
The sensor senses the engine coolant temperature

and sends the information to the engine control unit.
The sensor consists of a non-linear resistor, whose
P0015440 resistance varies with coolant temperature. The resist-
ance falls as the coolant temperature rises.
Sensor, common rail pressure (fuel)

The sensor is mounted on the right of the engine, at
the front of the common rail, which distributes fuel to
the injectors.
The rail pressure sensor senses the fuel pressure and

converts this to a voltage which is registered by the
engine control unit.
P0015441
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 pro-
portional to the pressure that the sensor measures.
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30-0 General
Magnetically controlled proportional

valve (MPROP)
A magnetically controlled proportional valve (MPROP)
controls the high pressure pump to ensure that the
correct fuel pressure (rail pressure) is retained despite
varying engine speed and loading.
The input signal to the valve is a PWM signal whose

pulse width is controlled by the engine control module.
When the current through the valve is changed, this

affects the fuel flow, which results in changed rail pres-
sure.
P0015443
Water in fuel switch, secondary fuel filter

A switch is located in the water trap under the fuel filter.
Its task is to detect whether there is water in the fuel.
The switch senses the resistance between two pins,

wich are in contact with the fuel. When there is no water
in the fuel, the resistance is very high. If there is any
water in the fuel, the resistance falls.
P0015442
Switch, coolant level

The task of the switch is to discover whether the cool-
ant level in the engine (expansion tank) has become
too low. An alarm signal is sent when the coolant level
is too low.
0016493
TAD752-754GE, TAD560-561VE,
TAD550-751GE TAD761-765VE
TAD734GE
P0015444
Preheater with preheater relay

The preheater is located in the inlet manifold at the left
side of the engine. The preheat relay is located at the
engines left side beneath the preheater.
P0015445
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30-0 General
Engine control unit, EMS 2

The engine control unit checks and controls the injec-
tors, to ensure that the correct volume of fuel is injected
into each cylinder at the right time. It also controls the
high pressure pump via the proportional valve
(MPROP) to ensure that the system always has the
correct fuel pressure (rail pressure).
A
B
The control unit also calculates and adjusts the injec-
tion advance. Regulation is mainly done with the aid of
the engine speed sensor and the combined sensor for
air inlet pressure/inlet manifold temperature.
The EMS 2 system processor is located in the control

unit, protected from water and vibration.
P0015446
The processor receives continuous information about:
• Engine Speed
• Throttle
• Oil Pressure
• Air inlet pressure/temperature
• Fuel pressure (common rail pressure)
• Fuel alarm, “Water in Fuel”
• Camshaft position
• Coolant temperature
The information provides information about current
operation conditions and allows the processor to cal-
culate the correct fuel volume, monitor engine status
etc.
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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 elec-
tronics.
IMPORTANT!
The system must be disconnected from system volt-
age (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 run-
ning.
• 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
P0013966 engine or in such a way that current can pass
through a bearing.
IMPORTANT!
After welding is completed, the disconnected com-
ponents, 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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30-0 General
Changing the engine control unit

IMPORTANT!
The system must be disconnected from system
voltage when the engine control module connec-
tors are disconnected or connected*.
2 Remove the two connectors from the engine con-
trol unit. Turn the locking arm down at the same
time as the connector is pulled outwards
3 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.
P0013967
47702487 11-2012 © AB VOLVO PENTA 33

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 “Service & Warranty > VODIA > ECU programming”.
3 Follow the instructions under “Select Chassis ID”.
Choose the control units to be reprogrammed and download the software.
The software for the control units is now downloaded to the PDA(1).
4 Take a look under “Settings”, “Software information” in VODIA to check that the
software has been downloaded.
5 Connect the VODIA to the engine (control unit) to be programmed.
6 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.
7 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).
8 Choose “VODIA” in the left-hand menu.
9 Choose “Report software” in the left-hand menu.
10 Follow the instructions for “Report software”.
Click “Report”.
1. PDA = “Personal Digital Assistant” (palmtop computer).
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30-0 General
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 34.
If the part numbers do not coincide – proceed as pos-

sible:
1 Have both part numbers available.
2 Log in to Volvo Penta Partner Network’s web site:
www.vppn.com
3 Choose “Service & Warranty > VODIA > Conver-
sion kit / Accessory kit wizard”.
4 Select engine type and function.
5 Select conversion kit(s) and chassis ID.
6 All selections will be shown in a summary. Click
continue if they are correct.
7 Volvo Penta’s database is now updated. It can take
about a minute before a confirmation is sent.
8 Programming of the control unit can now start.
Please refer to Reprogramming a control
unit page 34.
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30-0 General
Checking the starter motor voltage

Tools:
88890074 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 12.7 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 88890074 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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30-0 General
Checking the charging system

Tools:
88890074 Multimeter
Generally about alternators: Fault tracing charging system

The voltage output from an alternator must be limited
Battery check
to prevent the elecrolyte in the battery to evaporate.
The alternator output is regulated (limited) by the volt- 1 Check that all connectors at the battery are cor-
age regulator in the alternator. The maximum current rectly assembled.
that the alternator can deliver at regulated voltage
2 Check the condition of the cables to the battery.
output depends on the alternator revolution. When the
engine is started an excitation current is needed to 3 Check the water level in the battery.
“wake up” the alternator.
4 Check, if possible, the specific gravity of all cells.
NOTICE! It is the consumers (batteries included)
when no charge
which decides the output current from the alternator.
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.
Measurements when undercharge
1 Engine off. 1 Check the alternator belt tension.
2 Use 88890074 Multimeter to do a voltage meas- 2 Check that all connectors at the alternator and
urement over the battery. The nominal voltage at the battery are correctly assembled.
over a full loaded battery is approx. 12.7 V. 3 Check the condition of all cables in the charging
3 Engine on. Run at 1500 rpm. system.
4 Use 88890074 Multimeter to do a voltage meas- 4 Regulator fault. Replace regulator.

urement over the battery and also over the alter-
when overcharge
nator. The nominal charging voltage over the
batteries should be approx. 27.8-28.6 V. 1 Probably regulator fault. Replace regulator.
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30-0 General
Rail pressure measurement

This measurement is used for measuring the rail pres-
V sure. For example if the engine doesn´t start this meas-
urement can show the rail pressure while the engine is
cranking. If it is air in the system the rail pressure could
be too low for the engine control unit to activate injec-
tion.
1 NOTICE! Starter key in position 0.
2 Undo the connector from the sensor.
3 Connect adapter cable (885675) between the sen-
sor and the EECU.
4 Use multimeter (88890074) for voltage measure-
ment. Connect the COM from the multimeter to
measurement point 1. Connect V from the multi-
meter to measurement point 2.
5 NOTICE! Starter key in position I. The multimeter
should now show 0.5 Volt which is equal to 0 Mpa
(0bar).
6 When cranking the engine, read the voltage value
75 on the multimeter and look in the table which pres-
8856
sure the voltage equals.
5
4
3
2
1
2 NOTICE! To activate injection a rail pressure of at least

1 25 MPa (250 bar) is demanded.
P0013317
Voltage 0.5 0.95 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7
MPa 0 20.3 22.5 27.0 31.5 36.0 40.5 45.0 49.5 54.0
Bar 0 203 225 270 315 360 405 450 495 540
PSI 0 2944 3263 3916 4569 5221 5874 6527 7179 7832
Voltage 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7
MPa 58.5 63.0 67.5 72.0 76.5 81.0 85.5 90.0 94.5 99.0
Bar 585 630 675 720 765 810 855 900 945 990
PSI 8485 9137 9790 10440 11100 11750 12400 13050 13710 14360
Voltage 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7
MPa 103.5 108.0 112.5 117.0 121.5 126.0 130.5 135.0 139.5 144.0
Bar 1035 1080 1125 1170 1215 1260 1305 1350 1395 1440
PSI 15010 15660 16320 16970 17620 18270 18930 19580 20230 20890
Voltage 3.8 3.9 4.0 4.1 4.2 4.3 4.4 4.5
MPa 148.5 153.0 157.5 162.0 166.5 171.0 175.5 180.0
Bar 1485 1530 1575 1620 1665 1710 1755 1800
PSI 21540 22190 22840 23500 24150 24800 25450 26110
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30-0 General
Manual fault tracing in bus cables

Tools:
88890074 Multimeter
IMPORTANT!
Cut the current with the main switch before the cables
are disconnected.
Use the multimeter to check the bus cables. The con-

ductors 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 multi-
meter 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 volt-
age 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 resist-
ance values given in the workshop manual are approx-
imate, 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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30-0 General
Malfunctions
Fault code information
• MID (“Message Identification Description”): • SID (“Subsystem Identification Description”):
The MID consists of a number which designates The SID consists of a number that designates a
the control unit that sent the fault code message. component to which the fault code relates (tach-
(e.g. the engine control unit). ometer, for example).
• PID (“Parameter Identification Description”): • PSID (“Proprietary SID”):
The PID consists of a number that designates a The same as the SID, but this is a Volvo-specific
parameter (value) to which the fault code relates component.
(oil pressure, for example).
• FMI (“Failure Mode Identifier”):
• PPID (“Proprietary PID”): FMI indicates the type of fault (please refer to
The same as the PID, but this is a Volvo-specific the FMI table below).
parameter.
• SPN
Suspect Parameter Number
FMI table
SAE standard
FMI Display text SAE text
0 “Value too high” Data valid but above normal operational range.
1 “Value too low” Data valid but below operational range.
2 “Faulty data” Data erratic, intermittent or incorrect
3 “Electrical fault” Voltage above normal or shorted high.
4 “Electrical fault” Voltage below normal or shorted to lower voltage.
5 “Electrical fault” Current below normal or open circuit.
6 “Electrical fault” Current above normal or short circuit to battery negative
7 “Mechanical fault” Mechanical system not responding properly
8 “Mechanical or electrical fault” Abnormal frequency, pulse width or period
9 “Communication fault” Abnormal update rate
10 “Mechanical or electrical fault” Abnormally large variations
11 “Unknown fault” Unidentifiable error.
12 “Component fault” Faulty device or component
13 “Faulty calibration” Calibration value out of range.
14 “Unknown fault” Special instructions
15 – Data valid but above normal, too high - least severe level.
16 – Data valid but above normal, too high - moderately severe level.
17 – Data valid but below normal, too low - least severe level.
18 – Data valid but below normal, too low - moderately severe level.
19 – Received network data in error.
20-30 – Reserved for SAE assignment.
31 – Condition exist.
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30-0 General
Volvo specific for injectors (MID 128, SID 1-6)

FMI Help
3 Short circuit to battery voltage, injector low voltage side
4 Short circuit to battery negative, injector low voltage or high voltage side
5 Open circuit in injector circuit.
7 Mechanical system not responding properly
12 Low injector hold current
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30-0 General
General advice
NOTICE! The following must be done before fault trac-
ing 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 43.
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 sen-
sor.
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 stand-
ard for distributed systems.
The CAN bus consists of a pair of copper conductors

which are twisted 30 times per meter. The nodes com-
municate 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 acces-
sories and for diagnostics.
This is a serial bus in accordance with standard SAE

J1708.
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30-2 Fault Tracing
30-2 Fault Tracing
General
Fault tracing of cables and
connectors
Tools:
88890074 Multimeter
9998482 Measuring tool
Check all connectors visually
Check the following:

• Look for oxidation which can impair contact in con-
nectors.
• 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. Check the secondary 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 connec-
tor.
• Check the function of the secondary locking.
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30-2 Fault Tracing
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 dis-
connecting 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 measure-

ment, to find where the cable is damaged.
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 mal-
functions 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 88890074 Multimeter to measure the resist-
ance 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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30-2 Fault Tracing
Fault Codes
MID 128, PID 45 Inlet air heater
status
MID 128: Engine control unit
FMI 3 – Voltage above normal or short circuit to higher voltage

Fault code explanation: Faulty sensor / Faulty sensor circuit
Fault indication: DCU: Engine warning in DCU display.
CIU: Flash code
Flash code
Electrical fault: 5.4
Value fault: None
Symptom: Preheat relay never activated. White smoke for cold start. Start problems in
cold climate.
Conditions for fault code: The voltage on pin B25 on the EMS 2 is higher than normal.
Possible reason: Short circuit to B+ in cable harness between B25 and preheat relay.
Suitable action: 1 Check cable harness and connectors between B25 and preheat relay.
FMI 4 – Voltage below normal or short circuit to lower voltage

CIU: Flash code
Flash code
Value fault: None
Symptom: Induction air is hot. Preheat relay is impossible to turn off. Preheat fuse will
break.
Conditions for fault code: The voltage on pin B25 on the EMS 2 is lower than normal.
Possible reason: Short circuit to battery negative in cable harness between B25 and preheat
relay (the relay pulls).
Suitable action: 1 Check cable harness and connectors between B25 and preheat relay.
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30-2 Fault Tracing
FMI 5 – Current below normal or open circuit

CIU:Flash code
Flash code
Value fault: None
Symptom: Preheat relay never activated. White smoke for cold start. Start problems in
cold climate.
Possible reason: • Broken preheat relay.
• An open circuit in cable harness between B25 and preheat relay.
• An open circuit in cable harness between B57 and B60 and preheat
relay.
Suitable action: 1 Check that preheat relay coil is not broken.
2 Check the contact pressure in socket B25, socket B57 and B60 in the
engine connector.
3 Check cable harness and connectors between B25, B57 and B60 and
preheat relay.
Measurements: • Checking the preheat relay page 115
B Circuit description
In cold climate the intake air need too be preheated.
7 This is either done for GE engines by the preheater
25 1
A which is located in the inlet manifoldor or for VE
(+)57 2
engines by the glowplugs that are mounted in the cyl-
(+)60
inderhead. The preheat function is activated/deacti-
EMS2 vated by the engine control unit via the preheat relay.
P0015459 While the relay is not activated the potential on B25 is
A Preheat relay equal to battery voltage. When the preheat function is
B Connector B activated B25 alter its potential and the relay activates.
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.
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30-2 Fault Tracing
MID 128, PID 94 Fuel Delivery

Pressure
FMI 1 – Data valid but below operational range

Fault code explanation: Fuel pressure is too low.
CIU: Flash code
Flash code
Value fault: 3.8
Symptom: None.
Conditions for fault code: The fuel pressure alarm depends on the engine revolution.
Suitable action: 1 Check fuel level.
2 Open all fuel cocks and check that no leakage occurs.
3 Check drive belt adjustment.
4 Change all fuel filters. (pre- and fine filter)
5 Check that no fuel hose is squeezed or folded.
6 Check function of fuel pressure sensor by control measuring the fuel
pressure. (see workshop manual)
7 Check fuel feed pump.
8 Change fuel pressure release valve. (see workshop manual)
Measurements: • Checking fuel pressure sensor page 117
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30-2 Fault Tracing

Fault code explanation: Faulty sensor / Fault in sensor circuit
CIU: Flash code
Flash code
Value fault: 3.8
Symptom: None.
Conditions for fault code: The voltage on pin B16 on the EMS 2 is more than 4,75 Volt.
Possible reason: • An open circuit in fuel sensor negative cable.
• Short circuited fuel sensor signal cable to 5V voltage or to battery volt-
age.
• Faulty sensor.
Suitable action: 1 Check contact pressure in socket 18 in the engine connector B. Also
check contact pressure in connector at fuel pressure sensor.
2 Check cable harness and connectors between fuel sensor and EMS 2.
3 Check function of fuel pressure sensor.
Measurements: • Checking supply cable, fuel sensor page 115
• Checking negative cable, fuel sensor page 116
• Checking signal cable, fuel sensor page 117
• Checking fuel pressure sensor page 117

Fault code explanation: Faulty sensor / Fault in sensor circuit
CIU: Flash code
Flash code
Value fault: 3.8
Symptom: None.
Conditions for fault code: The voltage on pin B16 on the EMS 2 is less than 0.07 Volt.
Possible reason: • An open circuit in fuel sensor 5V supply cable.
• An open circuit in fuel sensor signal cable.
• Short circuited sensor signal cable to battery negative.
• Faulty sensor.
Suitable action: 1 Check contact pressure in socket 16 and 17 in the engine connector B.
Also check contact pressure in connector at fuel pressure sensor.
2 Check cable harness and connectors between fuel sensor and EMS 2.
3 Check function of fuel pressure sensor.
Measurements: • Checking supply cable, fuel sensor page 115
• Checking negative cable, fuel sensor page 116
• Checking signal cable, fuel sensor page 117
• Checking fuel pressure sensor page 117
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30-2 Fault Tracing
FMI 7 – Mechanical fault. The system responds incorrectly.

Fault code explanation: Fuel pressure is critically low
CIU: Flash code
Flash code
Value fault: 3.8
Symptom: None.
Conditions for fault code: The fuel pressure alarm depends on the engine revolution.
Suitable action: 1 Check fuel level.
2 Open all fuel cocks and check that no leakage occurs.
3 Check drivebelt adjustment.
4 Change all fuel filters. (pre- and fine filter)
5 Chech that no fuel hose is squeezed or folded.
6 Check functionof fuel pressure sensor by control measuring the fuel
pressure. (see workshop manual)
7 Check fuel feed pump.
8 Change fuel pressure release valve. (see workshop manual)
Measurements: • Checking fuel pressure sensor page 117
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30-2 Fault Tracing
The sensor is an active sensor, i.e. the sensor must
R 4 1
(+)17
SB
16 16 receive operating voltage. Pin B17 on the engine con-
10 10 A
(-)18
GN/BL P2 trol unit provides pin 1 on the sensor with an operating
16 17 17
voltage of +5 Volt. Pin 4 on the sensor is connected to
battery negative via pin B18 on the engine control unit.
EMS2 The output signal from the pressure sensor, pin 2 on
P0015460 the sensor to pin B16 on the EMS 2, is a voltage signal
A Fuel pressure sensor that is proportional to the fuel pressure.
B Connector B
NOTICE!
Only TAD650/660/750/760VE has a 42-pole connector. On
TAD734GE the wiring to the EMS 2 is the same but without any 42-
pole connector.
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 at 0 bar = 0 kPa
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30-2 Fault Tracing
MID 128, PID 97 Water in fuel

indicator
FMI 0 – Data valid but above normal operational range

Fault code explanation: Water in Fuel
CIU: Flash code
Flash code
Value fault: 2.1
Symptom: None
Conditions for fault code: Water in the fuel trap has been detected.
Suitable action: 1 Empty the water trap.
2 Check function of water in fuel switch.
Measurements: • Checking water in fuel switch page 119

Fault code explanation: Faulty sensor / Faulty circuit
CIU: Flash code
Flash code
Value fault: 2.1
Symptom: None
Conditions for fault code: The voltage signal on B8 is too high.
Possible reason: The cable connected to B8 is short circuited to battery voltage.
Suitable action: 1 Check cable harness and connectors between water in fuel switch and
EMS 2.
Measurements: • Checking supply cable, water in fuel switch page 118
• Checking negative cable, water in fuel switch page 118
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30-2 Fault Tracing

Fault code explanation: Faulty sensor / Faulty circuit
CIU: Flash code
Flash code
Value fault: 2.1
Symptom: None
Conditions for fault code: The voltage signal on B8 is too low.
Possible reason: • Short circuit between both cables to the water in fuel switch.
• The cable connected to B8 is short circuited to battery negative.
Suitable action: 1 Check cable harness and connectors between water in fuel monitor and
EMS 2.
Measurements: • Checking supply cable, water in fuel switch page 118
• Checking negative cable, water in fuel switch page 118
B
A Circuit description
A switch is located in the water trap under the fuel filter.
splice Its task is to detect whether there is water in the fuel.
10
SB
The switch senses the resistance between two pins,
8
Y wich are in contact with the fuel. When there is no water
EMS2 in the fuel, the resistance is very high. If there is any
P0015457
water in the fuel, the resistance falls.
A Water in Fuel
B Connector B At a threshold resistance (water has been detected),
the switch output signal (yellow cable) to the engine
control unit pin B8 will be pulled down to zero.
P0015458
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30-2 Fault Tracing
MID 128, PID 100 Engine oil pressure


Fault code explanation: Oil pressure is too low
Fault indication: DCU: Engine warning in DCU display
CIU: Flash code
Flash code
Value fault: 6.6
Symptom: Power is reduced due to error torque map if engine protection parameter is
activated.
Conditions for fault code: Oil pressure depends on the engine revolution. Oil pressure exceeds the set
value of the engine protection parameter.
Possible reason: • Too low engine oil level.
• Blocked oil filter.
• Oil leakage.
• Faulty oil pressure sensor.
Suitable action: 1 Check engine oil level and 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 function of oil pressure sensor by control measuring the engine
oil pressure (see workshop manual Group 21-26).
Measurements: • Checking oil pressure sensor page 121

CIU: Flash code
Flash code
Value fault: 6.6
Symptom: None
Conditions for fault code: The voltage on pin B11 on the EMS 2 is more than 4.95 Volt.
Possible reason: • Short circuit between signal cable and 5V supply to oil pressure sensor.
• Faulty sensor.
Suitable action: 1 Check cable harness and connectors between oil pressure sensor and
EMS 2.
2 Check function of oil pressure sensor.
Measurements: • Checking supply cable, oil pressure sensor page 119
• Checking negative cable, oil pressure sensor page 120
• Checking signal cable, oil pressure sensor page 120
• Checking oil pressure sensor page 121
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 6.6
Symptom: None
Possible reason: • An open circuit in 5V supply cable to oil pressure sensor.
• An open circuit in signal cable to oil pressure sensor.
• Short circuit between signal cable and battery negative to oil pressure
sensor.
• Faulty sensor.
Suitable action: 1 Check contact pressure in socket 11 and 17 in engine connector B. Also
check contact pressure in connector at oil pressure sensor.
2 Check cable harness and connectors between oil pressure sensor and
EMS 2.
3 Check function of oil pressure sensor.
Measurements: • Checking supply cable, oil pressure sensor page 119
• Checking negative cable, oil pressure sensor page 120
• Checking signal cable, oil pressure sensor page 120
• Checking oil pressure sensor page 121
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30-2 Fault Tracing
TAD650/660/750/760VE
R receive operating voltage. Pin B17 on the engine con-
(+)17 33 33 1
(-)18
SB
27 27 3 A trol unit (EMS 2) provides pin 1 on the sensor with an
BL/OR P2 operating voltage of +5 Volt. Pin 3 or pin 4 (depended
11 26 26
of engine type) on the sensor is connected to battery
C negative via pin B18 on the EMS 2.
EMS2
The output signal from the pressure sensor, pin 2 on
P0015461
A Oil pressure sensor
the sensor to pin B11 on the EMS 2, is a voltage signal
that is proportional to the oil pressure (after the oil fil-
B Connector B ters).
C 42-pin connector
TAD734GE
B
(+)17 R 1
SB A
(-)18 4
BL/OR P2
11
EMS2
P0015462
A Oil pressure sensor
B Connector B
Working range: 0 – 7 bar = 0 – 700 kPa

5.00 VDC:
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30-2 Fault Tracing
MID 128, PID 105 Intake manifold

temperature

Fault code explanation: Inlet manifold temperature is too high
CIU: Flash code
Flash code
Value fault: 6.2
Symptom: Engine is derated if engine protection parameter is activated.
Conditions for fault code: Inlet manifold temperature exceeds the set value of the engine protection
parameter.
Possible reason: • Engine temperature is too high.
• High surrounding temperature.
• Dust or dirt on the outside of the intercooler.
• Faulty inlet manifold temperature sensor.
Suitable action: 1 Check that engine temperature is normal.
2 Clean the intercooler.
3 Check function of inlet manifold temperature sensor.
Measurements: • Checking inlet manifold temperature sensor page 124

CIU: Flash code
Flash code
Value fault: 6.2
Symptom: Temperature is set to 40° C.
Possible reason: • Short circuited sensor signal cable to battery negative.
• Faulty sensor.
Suitable action: 1 Check cable harness and connectors between inlet manifold tempera-
ture sensor and EMS 2.
Measurements: • Checking signal cable, inlet manifold temperature sensor page 121
• Checking negative cable, inlet manifold pressure/temperature
sensor page 122
• Checking sensor cable, inlet manifold temperature sensor page 123
• Checking inlet manifold temperature sensor page 124
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 6.2
Symptom: Temperature is set to 40° C.
Possible reason: • An open circuit in 5V supply cable to sensor.
• An open circuit in inlet manifold temperature signal cable.
• Short circuited sensor signal cable to 5V voltage or to battery voltage.
• Faulty sensor.
Suitable action: 1 Check contact pressure in socket 47 and 7 in engine connector A. Also
check contact pressure in connector at boost temperture sensor.
2 Check cable harness and connectors between inlet manifold tempera-
ture sensor and EMS 2.
Measurements: • Checking signal cable, inlet manifold temperature sensor page 121
sensor page 122
• Checking sensor cable, inlet manifold temperature sensor page 123
• Checking inlet manifold temperature sensor page 124
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30-2 Fault Tracing
(+) 7
R 22 22 The inlet manifold temperature sensor consists of a
SB 1 3
(-)11 28 28 thermistor which forms a closed circuit with an internal
B
GR/GN P4 2 resistor in the engine control unit (EMS 2), via the
22 23 23
47
BN/OR
29 29
engine interface. The thermistor resistor changes in a
non-linear manner, depending on the inlet manifold
C temperature.
EMS2
P0015463
A Connector A
B Sensor for air inlet pressure / inlet manifold temperature
C 42-pin connector
NOTICE!
Only TAD650/660/750/760VE has a 42-pin connector.
The EMS 2 provides the circuit with a reference voltage

of +5 Volt. The EMS 2 measures the voltage drop over
the thermistor via pin A47 and pin A11 on the EMS 2.
Pin 1 on the sensor is connected to battery negative
via pin A11 on the EMS 2.
When the boost air is cold, the thermistor resistance is

high and the EMS 2 senses a high voltage drop. As the
boost air warms up, the resistance in the thermistor
falls and the voltage drop across it falls.
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30-2 Fault Tracing
MID 128, PID 106 Air inlet pressure


Fault code explanation: Air inlet pressure is too high
CIU: Flash code
Flash code
Value fault: 3.5
Symptom: Power is reduced due to error torque map if engine protection parameter is
activated.
Conditions for fault code: Air inlet pressure exceeds the set value of the engine protection parameter.
Possible reason: • The wastegate does not function properly.
• Faulty air inlet pressure sensor.
• Wrong turbo compressor unit according to the engine specification.
Suitable action: 1 Check wastegate functionality (see workshop manual Group 21-26).
2 Check function of air inlet pressure sensor by control measuring air inlet
pressure using a measuring tap (see workshop manual Group 21-26).
3 Check that turbo compressor unit is in according to the engine specifi-
cation.
Measurements: • Checking air inlet pressure sensor page 125

CIU: Flash code
Flash code
Value fault: 3.5
Symptom: Pressure set to atmospheric pressure + 30 kPa. Engine performance is
derated.
Conditions for fault code: The voltage on pin A22 on the EMS 2 is more than 4.75 Volt.
Possible reason: • Short circuited sensor signal cable to 5V voltage or battery voltage.
• Faulty sensor.
Suitable action: 1 Check cable harness and connectors between air inlet pressure sensor
and EMS 2.
2 Check function of air inlet pressure sensor.
Measurements: • Checking supply cable, inlet manifold pressure sensor page 124
sensor page 122
• Checking signal cable, inlet manifold pressure sensor page 125
• Checking air inlet pressure sensor page 125
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 3.5
Symptom: Pressure set to atmospheric pressure + 30 kPa. Engine performance is
derated.
Conditions for fault code: The voltage on pin A22 on the EMS 2 is less than 0.07 Volt.
Possible reason: • An open circuit in air inlet pressure signal cable.
• An open circuit in sensor negative cable.
• Short circuited air inlet pressure signal cable to sensor negative cable.
• Faulty sensor.
check contact pressure in connector at air inlet pressure sensor.
2 Check cable harness and connectors between air inlet pressure sensor
and EMS 2.
3 Check function of air inlet pressure sensor.
Measurements: • Checking supply cable, inlet manifold pressure sensor page 124
sensor page 122
• Checking signal cable, inlet manifold pressure sensor page 125
• Checking air inlet pressure sensor page 125
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30-2 Fault Tracing
(+) 7
R 22 22 The sensor is an active sensor, i.e. the sensor must
SB 1 3
(-)11 28 28 receive operating voltage. The air inlet pressure sen-
B
GR/GN P4 2 sor measures the absolute pressure, which is the sum
22 23 23
47
BN/OR
29 29
of the air inlet pressure and atmospheric pressure (300
kPa thus corresponds to a air inlet pressure of 200 kPa
C when atmospheric pressure is 100 kPa).
EMS2
P0015463
A Connector A Pin A7 on the engine control unit (EMS 2) provides pin
B Sensor for air inlet pressure / inlet manifold temperature
3 on the sensor with an operating voltage of +5 Volt.
Pin 1 on the sensor is connected to battery negative
C 42-pin connector via pin A11 on the EMS 2. The output signal from the
NOTICE! pressure sensor, pin 4 on the sensor to pin A22 on the
Only TAD650/660/750/760VE has a 42-pin connector. EMS 2, is a voltage signal that is proportional to the air
inlet pressure.
Working range: 0,5 – 4,0 bar = 50 – 400 kPa

5,00 VDC:
0,5 VDC at 0,5 bar = 50 kPa
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30-2 Fault Tracing
MID 128, PID 108 Barometric

pressure
FMI 2 – Data erratic, intermittent or incorrect

Fault code explanation: Plausibility
Fault indication: DCU: None
CIU: None
Flash code
Electrical fault: None
Value fault: None
Symptom: None.
Conditions for fault code: Internal fault in the engine control unit.
Suitable action: 1 Replace the engine control unit (EMS 2).

CIU: None
Flash code
Value fault: None
Symptom: Ambient pressure is set to 1.0 bar.

CIU: None
Flash code
Value fault: None
Symptom: Ambient pressure is set to 1.0 bar.
Component description
Sensor is placed inside the engine control unit and is
not replaceable.
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30-2 Fault Tracing
MID 128, PID 110 Engine coolant

temperature

Fault code explanation: Coolant temperature too high.
CIU: Flash code
Flash code
Value fault: 6.1
Symptom: Engine is derated if engine protection parameter is activated.
Conditions for fault code: Coolant water temperature exceeds the set value of the engine protection.
Possible reason: • Coolant level too low.
• Dust or dirt on the outside of the radiator.
• Drive belt is not properly adjusted.
• There is air in the coolant water system.
• Faulty thermostat.
• Faulty temperature sensor.
• Clogged cooling water system.
Suitable action: 1 Check coolant level.
2 Check outside of the radiator for dust and dirt.
3 Check drive belt adjustment.
4 Bleed coolant water system.
5 If low coolant level check coolant water system for leakage by a pres-
sure test.
6 Check coolant pressure valve in the coolant cup or try with another
coolant cup.
7 Check coolant water thermostat or change coolant water thermostat.
8 Check function of coolant temperature sensor.
9 Clean cooling water system.
Measurements: • Checking coolant temperature sensor page 141
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 6.1
Symptom: Engine is difficult to start
Possible reason: • Short circuit between both cables to the coolant temperature sensor.
• Faulty sensor.
Suitable action: 1 Check cable harness and all connectors between coolant temperature
sensor and EMS 2.
Measurements: • Checking negative cable, coolant temperature sensor page 138
• Checking signal cable, coolant temperature sensor page 139
• Checking sensor cable, coolant temperature sensor page 140
• Checking coolant temperature sensor page 141

CIU: Flash code
Flash code
Value fault: 6.1
Symptom: Engine is difficult to start
Possible reason: • Open circuit in signal cable to temperature sensor.
• Open circuit in negative cable to temperature sensor.
• Faulty sensor.
Suitable action: 1 Check contact pressure in socket 18 and 27 in engine connector B.
Check also contact pressure in connector at coolant temperature sen-
sor.
2 Check cable harness and all connectors between coolant temperature
sensor and EMS 2.
Measurements: • Checking negative cable, coolant temperature sensor page 138
• Checking signal cable, coolant temperature sensor page 139
• Checking sensor cable, coolant temperature sensor page 140
• Checking coolant temperature sensor page 141
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30-2 Fault Tracing
The coolant temperature sensor consists of a thermis-
2
(-)10 30 30 tor which forms a closed circuit with an internal resistor
SB A
27
24 24 1 in the engine control unit (EMS 2) via the engine inter-
GR/W
C face. The thermistor resistor changes in a non-linear
manner, depending on the coolant temperature. The
EMS2 EMS 2 provides the circuit with a reference voltage of
P0015464 +5 Volt. The EMS 2 measures the voltage drop over
A Coolant temperature sensor the thermistor via pin B27 and pin B18 on the EMS 2.
B Connector B Pin 1 on the sensor is connected to battery negative
via pin B18 on the EMS 2. When the coolant is cold,
C 42-pin connector
the thermistor resistance is high and the EMS 2 senses
NOTICE! a high voltage drop. As the coolant warms up, the
Only TAD650/660/750/760VE has a 42-pin connector. resistance in the thermistor falls and the voltage drop
across it falls.
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30-2 Fault Tracing
MID 128, PID 111 Coolant level


Fault code explanation: Coolant level is too low.
CIU: Flash code
Flash code
Value fault: 2.2
Symptom: VE engines: Engine is derated if engine protection parameter is activated.
GE engines: Engine is shutdown.

Suitable action: 1 Check coolant level.
2 Bleed coolant water system.
3 If low coolant level check coolant water system for leakage by a pres-
sure test.
4 Check pressure valve in the coolant cup or try with another coolant cup.
5 Check wiring to the coolant level switch.
6 Check function of coolant level switch.
Measurements: • Checking coolant level switch page 127

CIU: Flash code
Flash code
Value fault: 2.2
Symptom: None
Conditions for fault code: The voltage on pin B23 in the engine control unit is too high.
Possible reason: Short circuit to battery voltage on pin B23.
Suitable action: 1 Check cable harness and connectors between coolant level monitor
and EMS2.
Measurements: • Checking supply cable, coolant level switch page 126
• Checking negative cable, coolant level switch page 126
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30-2 Fault Tracing
The coolant level in the engine is monitored by a level
10
SB
2 switch. Pin B23 on the engine control unit (EMS 2)
A
1 provides pin 1 on the level switch with a voltage. Pin 2
on the level switch is connected to battery negative via
23
LBN
pin B10 on the engine control unit.
EMS2
P0015465 The level switch has two states: On/Off.
A Coolant level switch
The level switch consists of two sections, the actual
B Connector B switch and a magnetic float which is built into the
expansion tank. The switch senses the position of the
magnetic float. There are two different switches
depended of engine type. The one on
TAD650/660/750/760VE engines works as follow:
when the coolant level falls, the float operates the
switch and a closed circuit is formed.
The one on TAD734GE, TAD550/551GE,

TAD750-754GE, TAD560/561VE and TAD761-765VE
engines works as follow: when the coolant level falls,
the float operates the switch and an open circuit is
formed
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30-2 Fault Tracing
MID 128, PID 158 ECU battery

potential

Fault code explanation: Voltage too low
CIU: Flash code
Flash code
Electrical fault: None (EMS)
Value fault: 3.9 (EMS)
Electrical fault: None (CIU)
Value fault: 6.9 (CIU)
Symptom: Could be engine starting problems.
Conditions for fault code: Battery voltage less than 25.5V, engine running.
Possible reason: • Altenator belt
• Flat / poor batteries
• Fault in cables or connectors for battery / altenator
• Faulty altenator
Suitable action: 1 Check battery cables and connections.
2 Check / charge batteries.
3 Check altenator and drive belt.
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30-2 Fault Tracing
MID 128, PID 164 Injection Control

Pressure

Fault code explanation: Sensor out of range
CIU: None
Lamp status
FMI 0: None
FMI 2,4,5: Yellow lamp
Flash code
Value fault: None
Symptom: None
Conditions for fault code: Rail pressure depends on engine revolution and engine load.
Possible reason: • Faulty MROP.
• Faulty rail pressure sensor.
Suitable action: 1 Check MPROP cables and connectors.
2 Check function of rail pressure sensor.
Measurements: • Checking injection control pressure sensor page 144

Fault code explanation: Plausibility
CIU: None
Lamp status
FMI 0: None
Flash code
Value fault: None
Symptom: Engine speed limitation (1100rpm).
Full fuel flow delivery, limp home with pressure release valve opened. An
estimated rail pressure with depending to fuel quantity will be used.
Conditions for fault code: Plausibility fault.
Possible reason: • Faulty rail pressure sensor.
Suitable action: 1 Check function of rail pressure sensor.
Measurements: • Checking injection control pressure sensor page 144
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30-2 Fault Tracing

CIU: None
Lamp status
FMI 0: None
Flash code
Value fault: None
Conditions for fault code: The voltage on pin A19 on the EMS 2 is less than 0.07 Volt.
Possible reason: • Short circuited sensor signal cable to battery negative.
Suitable action: 1 Check cable harness and connectors between rail pressure sensor and
EMS 2.
Measurements: • Checking supply cable, rail pressure sensor page 142
• Checking negative cable, rail pressure sensor page 142
• Checking signal cable, rail pressure sensor page 143
• Checking injection control pressure sensor page 144
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30-2 Fault Tracing

CIU: None
Lamp status
FMI 0: None
Flash code
Value fault: None
Conditions for fault code: The voltage on pin A19 on the EMS 2 is more than 4.95 Volt.
Possible reason: • An open circuit in rail sensor 5V supply cable.
• An open circuit in rail sensor negative cable.
• An open circuit in rail sensor signal cable.
• Short circuited sensor signal cable to 5V supply cable.
• Short circuited sensor negative cable to 5V supply cable.
Suitable action: 1 Check contact pressure in socket 7, 11 and 19 in engine connector A.
Also check contact pressure in connector at fuel pressure sensor.
2 Check cable harness and connectors between rail pressure sensor and
EMS 2.
Measurements: • Checking supply cable, rail pressure sensor page 142
• Checking negative cable, rail pressure sensor page 142
• Checking signal cable, rail pressure sensor page 143
• Checking injection control pressure sensor page 144
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30-2 Fault Tracing
splice
R 22 22 3
(+)7 1 receive operating voltage. Pin A7 on the engine control
SB splice
(-)11 28 28 B
P2 unit (EMS 2) provides pin 3 on the sensor with an oper-
19 25 25
ating voltage of +5 Volt. Pin 1 on the sensor is con-
C nected to battery negative via pin A11 on the EMS 2.
EMS2 The output signal from the pressure sensor, pin 2 on
P0015466 the sensor to pin A19 on the EMS 2, is a voltage signal
A Connector A that is proportional to the rail pressure.
B Rail pressure sensor
C 42-pin connector
NOTICE!
Working range: 0 – 1800 bar = 0 – 180 MPa
Supply voltage: 5.00 +/- 0.25 VDC

5.00 VDC:
0.5 VDC at 0 bar = 0 kPa
4.5 VDC at 1800 bar = 180 MPa
P0005685
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30-2 Fault Tracing
MID 128 / 144, PPID 4 Starter input

sensor
MID 144: CIU

Fault code explanation: Faulty circuit.
CIU: Flash code
Flash code
Electrical fault: 4.7 (EMS)
Value fault: None (EMS)
Electrical fault: 5.2 (CIU)
Value fault: None (CIU)
Symptom: The engine starts cranking immediately when ignition is turned on.
Possible reason: Faulty start switch.
Suitable action: 1 Check that start switch is connected correctly.
2 Check cable harness and connectors between CIU and start switch.
3 Check function of start switch.

CIU: Flash code
Flash code
Symptom: The engine cannot be started.
Possible reason: • Short circuited CIU start signal cable to battery negative.
• Faulty start switch.
Suitable action: 1 Check that start switch is connected correctly.
2 Check contact pressure in socket 35 in the CIU connector.
3 Check cable harness and connectors between CIU and start switch.
4 Check function of start switch.
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30-2 Fault Tracing
MID 128 / MID 144, PPID 6 Key off

input sensor

CIU: Flash code
Flash code
Symptom: The engine can only be stopped by using AUX stop.
Possible reason: • Stop signal activated too long.
• Faulty stop button.
Suitable action: 1 Check that the stop button is not stucked.
2 Check that stop button is connected correctly.
3 Check cable harness and connectors at aux stop button at EMS / stop
button at CIU.
4 Check function of aux stop button at EMS / stop button at CIU.

CIU: Flash code
Flash code
Symptom: The engine can only be stopped by using AUX stop.
Possible reason: Short circuit to battery negative.
Suitable action: 1 Check cable harness and connectors at aux stop button at EMS / stop
button at CIU.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Symptom: Engine can’t be stopped.
Possible reason: An open circuit in aux stop circuit.
Suitable action: 1 Check cable harness and connectors at aux stop button at EMS / stop
button at CIU.
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30-2 Fault Tracing
MID 128, PPID 19 Internal EGR

Status

CIU: None
Flash code
Value fault: None
Symptom: IEGR can not be turned on.
Possible reason: • Short circuited IEGR signal cable to 5V voltage or to battery voltage.
Suitable action: 1 Check cable harness and connectors between EMS 2 and IEGR.
Measurements: • Checking the wiring page 129
FMI 4 – The voltage is less than the normal value or is short circuited to battery negative
CIU: None
Flash code
Value fault: None
Possible reason: • Short circuited IEGR signal cable to battery negative.

CIU: None
Flash code
Value fault: None
Possible reason: • An open circuit in one or both of the cables to the IEGR.
2 Check IEGR coil.
• Checking IEGR coil page 130
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30-2 Fault Tracing

Fault code explanation: Mechanical fault.
CIU: None
Flash code
Value fault: None
Symptom: May damage turbine, increased power and emissions.
Possible reason: • IEGR solenoid mechanically stucked.
• Too low oil pressure to activate the IEGR.
Suitable action: 1 Check function of IEGR solenoid.
2 Check engine oil pressure.
Measurements: • Checking IEGR solenoid page 130
B
Circuit description
30 R 12 12 2 Internal exhaust gas recirculation, IEGR, is like the
SB
(+)57 11 11
1
name says used for recirculation of exhaust gases.
(+)60
A This for lowering the emissions from the engine. The
EGR
IEGR valve is a 2-way solenoid valve controlled by the
EMS2 engine control unit. The IEGR solenoid controls a oil
P0015467 pressure that effects a control valve which activate the
A 42-pin connector exhaust gas recirculation function. The solenoid is acti-
B Connector B
vated when pin B30 on the EMS 2 changes its poten-
tial.
P0015439
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30-2 Fault Tracing
MID 128 / 144, PPID 132 Throttle

calibrated position

Fault code explanation: Faulty throttle potentiometer / Faulty throttle potentiometer circuit
CIU: Flash code
Flash code
Value fault: None
Symptom: 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.
Possible reason: • Open circuit in any or all of the throttle signals.
• Short circuited throttle potentiometer signal cable to 5V voltage or to
battery voltage.
• Faulty throttle potentiometer.
Suitable action: 1 Check that the throttle potentiometer is connected correctly.
2 Check cable harness and connectors between CIU and CIU throttle
potentiometer.
3 Check function of throttle potentiometer.
4 Check contact pressure in socket 2, 3 and 30 in CIU connector.
FMI 4 – The voltage is less than the normal value or is short circuited to battery negative
Fault code explanation: Faulty throttle potentiometer / Faulty throttle potentiometer circuit
CIU: Flash code
Flash code
Value fault: None
Possible reason: • Short circuited throttle potentiometer signal cable to battery negative.
• Faulty throttle potentiometer.
potentiometer.
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30-2 Fault Tracing
FMI 9 – Abnormal update rate

Fault code explanation: EMS2 is missing the throttle signal.
CIU: Flash code
Flash code
Value fault: None
Preconditions: NOTICE! If the control panel ONLY communicates on the J1939 communi-
cation and NOT the redundancy of J1587 for start, stop and throttle this fault
code is active in the VODIA and that is normal.
Conditions for fault code: EMS2 gets no throttle signal on the J1939 bus from the CIU.
potentiometer.
4 Check contact pressure in socket 2, 3 and 30 in CIU connector.
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30-2 Fault Tracing
MID 128, SID 1/2/3/4/5/6 Injector # 1-6

FMI 3 – Short to battery voltage, injector low voltage side

Fault code explanation: Fault in the injection system.
CIU: Flash code
Flash code
Electrical fault: 7.1– 7.6
Value fault: None
Symptom: Faulty injector is shut off. Limp home on rest of injectors.
Preconditions: NOTICE! Identify which injector by the SID number.
Conditions for fault code: Injector activated and faulty voltage in injector low side.
Possible reason: • Short circuit to battery voltage on the pin on the respective injector’s
low voltage side. (EMS 2 pin: 56, 52, 48 and 44, 40, 36)
• Short circuit between high voltage and low voltage sides.
• Short circuit to battery voltage in low voltage injector wire.
Suitable action: 1 Check cable harness and connectors between injectors and engine
control unit (EMS 2).
Measurements • Checking the injectors page 131
FMI 4 – Short to battery negative, injector high voltage side

CIU: Flash code
Flash code
Value fault: None
Conditions for fault code: Injector activated and faulty voltage in injector high side.
Possible reason: • Short circuit to battery negative on the pin on the respective injector’s
high voltage side. (EMS 2 pin: 59 and 60)
• Short circuit to battery negative in high voltage injector wire.
Suitable action: 1 Check cable harness and connectors between injectors and engine
control unit (EMS 2).
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30-2 Fault Tracing
FMI 5 – Break in injector circuit.

CIU: Flash code
Flash code
Value fault: None
Conditions for fault code: Injector activated and faulty voltage in injector high or low side.
Possible reason: • An 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. (EMS 2 pin: 59 and 60)
• Short circuit to battery negative on the pin on the respective injector’s low
voltage side. (EMS 2 pin: 56, 52, 48 and 44, 40, 36)
Suitable action: 1 Check contact pressure in socket 36, 40, 44 ,52, 56, 59 and 60 in engine
connector A.
2 Check cable harness and connectors between injectors and engine control
unit (EMS 2).

CIU: Flash code
Flash code
Electrical fault: 7.1–7.6
Value fault: None
Symptom: None
Conditions for fault code: 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.
Possible reason: • Unsymmetrical load of the engine.
• Poor / uneven compression.
• Faulty injector.
Suitable action: 1 Clear the fault code with the Vodia tool. Let the engine run at idle speed
without any load and see if the fault code reappear.
2 Perform test of cylinder compression using the VODIA tool.
3 Change only the faulty injector.
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30-2 Fault Tracing
FMI 12 – Low injector hold current

CIU: Flash code
Flash code
Value fault: None
Symptom: None
Conditions for fault code: Low injector hold current. Injector activated.
Possible reason: • Intermittent fault.
Suitable action: 1 Check cables harness and connectors between injector and engine
control unit.
FMI 14 – Special instructions

CIU: Flash code
Flash code
Value fault: None
Symptom: None
Conditions for fault code: Low or high flow through injector.
Possible reason: Faulty injector: leakage in spill valve, increased nozzle hole.
Suitable action: 1 Change only the faulty injector.
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30-2 Fault Tracing
A B Circuit description
Cyl 1
35 35
The electronic injectors used on the engine has an
W Cyl 2
56 36 36 electronically controlled solenoid. The solenoid is con-
W
52 trolled by the engine control unit.
W Cyl 3
48 37 37
(+)59
W
34 34 The injectors receive voltage from pin A59 or A60 on
W Cyl 4 the engine control unit. To activate an injector solenoid
44 39 39
the engine control unit grounds the current injector.
W Cyl 5
40 40 40
W
36
Cyl 6
W 41 41
(+)60
EMS2 42 42
P0015468
A Connector A
B 42-pin connector
NOTICE!
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30-2 Fault Tracing
MID 128, SID 21 Engine position


CIU: Flash code
Flash code
Value fault: None
Symptom: The engine start time will increase, uses only crankshaft sensor.
Conditions for fault code: Incorrect timing.
Possible reason: • Polarity fault. The cables to the cam sensor is shifted.
• Intermittent fault.
• Incorrectly mounted cam sensor.
Suitable action: 1 Check cable harness and connectors between cam sensor and EMS 2.
2 Check that the cam sensor is connected as in the circuit description.
3 Check contact pressure in socket 45 and 46 in engine connector A.
4 Check function of cam sensor.
Measurements • Checking camshaft sensor wiring page 132
• Checking camshaft sensor page 133

CIU: Flash code
Flash code
Value fault: None
Conditions for fault code: No sensor signal when expected.
Possible reason: 1 Incorrectly mounted cam sensor.
2 An open circuit in any or both of the cables to the cam sensor.
3 Short circuit between cables to cam sensor.
4 Faulty cam sensor.
Suitable action: 1 Check installation of cam speed sensor.
2 Check cable harness and connectors between cam sensor and EMS 2.
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30-2 Fault Tracing
FMI 8 – Abnormal frequency, pulse width or period

CIU: Flash code
Flash code
Value fault: None
Conditions for fault code: Incorrect sensor signal.
Possible reason: • Incorrectly mounted speed sensor.
• Electrical interference in the speed signal.
Suitable action: 1 Check wiring between cam sensor and EMS 2.
3 Check installation of cam sensor.
4 Attempt to localize the source of interference.
The camshaft sensor is an inductive sensor. When the
GR / SB
46
GR / SB
13 13 2 camshaft rotates impulses are created in the sensor
45 14 14 1 B
via a tooth wheel installed on the camshaft. The tooth
C wheel has 7 teeth, one for each cylinder + one to deter-
mine when cylinder one is to be injected. The impulses
EMS2 create a pulse signal in the sensor that the engine con-
P0015469 trol unit (EMS 2) uses to calculate when a cylinder is
A Connector A in turn for injection.
B Camshaft sensor
C 42-pin connector
NOTICE!
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30-2 Fault Tracing
MID 128, SID 22 Timing sensor,

crank

CIU: Flash code
Flash code
Value fault: None
Symptom: Engine is difficult to start, uses only cam sensor.
Conditions for fault code: Incorrect signal.
Possible reason: • Short circuit between cables to crankshaft sensor.
• Polarity fault. The cables to the crankshaft sensor is shifted.
Suitable action: 1 Check cable harness and connectors between crankshaft sensor and
EMS 2.
2 Check that crankshaft sensor is connected as in the circuit description.
3 Check function of crankshaft sensor.
Measurements • Checking crankshaft sensor wiring page 134
• Checking crankshaft sensor page 135

CIU: Flash code
Flash code
Value fault: None
Symptom: Engine is running with imprecise timing causing risk of high fuel consumption
and smoke. Cylinder balancing not working with risk of uneven running.
Conditions for fault code: No sensor signal when expected or permanent loss of sensor signal.
Possible reason: • Open circuit in any or both of cables to the crankshaft sensor.
• Incorrectly mounted crankshaft sensor.
• Faulty crankshaft sensor.
Suitable action: 1 Check cable harness and connectors between crankshaft sensor and
EMS 2.
3 Check installation of crankshaft sensor.
4 Check function and clean the crankshaft sensor.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: None
Symptom: Engine is difficult to start, uses only cam sensor.
Conditions for fault code: Incorrect crankshaft sensor signal.
Possible reason: • Incorrectly mounted crankshaft sensor.
• Electrical interference in the crankshaft sensor signal.
Suitable action: 1 Check wiring and connectors between crankshaft sensor and EMS 2.
3 Check installation of crankshaft sensor.
4 Attempt to localize the source of interference.
5 Check function and clean the crankshaft sensor.
The crankshaft speed sensor is an inductive sensor.
GR / SB 21 21 2
37
VO /SB When the crankshaft rotates impulses are created in
38 15 15 1 B
the sensor via a tooth wheel on or behind the torsion
C damper. The impulses create a pulse signal in the sen-
sor that the engine control unit (EMS 2) uses to calcu-
EMS2 late the crankshaft rpm.
P0015470
A Connector A The tooth wheel has a tooth free gap for the EMS 2 to
recognize the position of the crankshaft.
B Crankshaft sensor
C 42-pin connector
NOTICE!
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30-2 Fault Tracing
MID 128, SID 39 Engine Starter

Motor Relay
At starter motor problems:

• Check battery condition.
• Check wiring to start motor.
• Check that starter relay click when start button is
activated.

Fault code explanation: Fault in starter relay circuit
CIU: None
Flash code
Value fault: Flash code
Symptom: Start motor does not engage.
Conditions for fault code: Short circuit too battery voltage.
Possible reason: • Short circuit in starter relay cable.
• Faulty starter relay.
Suitable action: 1 Check cable harness and connections between starter relay and EMS
2.
2 Check function of starter relay.
Measurements: • Checking starter motor relay coil page 128
• Checking starter motor relay voltage supply page 128
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30-2 Fault Tracing

CIU: None
Flash code
Conditions for fault code: Short circuit too battery negative.
Possible reason: • Short circuit in starter relay cable.
2.

CIU: None
Flash code
Conditions for fault code: Open Circuit
Possible reason: • An open circuit in starter relay cable.
2.
2 Check contact pressure in socket B29 in engine connector.
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30-2 Fault Tracing
The starter relay is located on the starter motor. When
ignition is on, the starter relay receives battery voltage
29 2 2 -
A from B57 and B60. B29 is not activated. When the start
(+)57 3 3 +
button is activated B29 alter its potential and the relay
(+)60
C activates.
EMS2
P0015471
A Starter motor relay
B Connector B
C 42-pin connector
NOTICE!
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30-2 Fault Tracing
MID 128, SID 42 Fuel control unit


Fault code explanation: Faulty regulator / Faulty regulator circuit
CIU: None
Flash code
Electrical fault:8.3
Value fault: None
Symptom: Full fuel flow delivery. Limp home with pressure release valve opened.
Possible reason: Short circuit to battery voltage in MPROP negative cable, pin 2 on MPROP.
Suitable action: 1 Check cable harness and connectors between EMS 2 and MPROP.
Measurements • Checking the wiring to the MPROP valve page 145
• Checking the solenoid in the MPROP valve page 146

CIU: None
Flash code
Value fault: None
Possible reason: Short circuit to battery negative in MPROP positive wire, pin 1 on MPROP.
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30-2 Fault Tracing

CIU: None
Flash code
Value fault: None
Symptom: • Full fuel flow delivery. Limp home with pressure release valve opened.
• Possible stall of engine.
Possible reason: • An open circuit in one or both cables from EMS 2 to MPROP.
• Short circuit to battery negative in MPROP positive wire, pin 1 on
MPROP.
• Short circuit between both wires to MPROP.
• Short circuit to battery voltage in MPROP positive wire, pin 1 on
MPROP.
check contact pressure in connector at MPROP.
2 Check cable harness and connectors between EMS 2 and MPROP.
FMI 6 – Current above normal or short circuit to battery negative

CIU: None
Flash code
Value fault: None
Possible reason: • Short circuit to battery negative in MPROP negative cable, pin 2 on
MPROP.
• An open circuit in one or both cables from EMS 2 to MPROP.
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30-2 Fault Tracing
FMI 13 – Calibration value of range

CIU: None
Flash code
Value fault: None
Symptom: • Full fuel flow delivery. Limp home with pressure release valve opened.
• Possible stall of engine.
Possible reason: Short circuit to battery negative in MPROP negative cable, pin 2 on MPROP.
A
- 2
Circuit description
16 20 20
A magnetically controlled proportional valve (MPROP)
B
controls the fuel pressure (rail pressure) to ensure that
12 19 19
+ 1 the correct fuel pressure is retained despite varying
C engine speed and loading. Signal from engine control
EMS2 unit is a PWM signal (pulse width modulated signal).
P0015472 When the current through the valve is changed, this
A Connector A affects the fuel flow, which results in changed rail pres-
B MPROP sure. The rail pressure sensor senses the pressure
and converts the pressure signal to a voltage which is
C 42-pin connector
registered by the engine control unit. If the current to
NOTICE! the valve solenoid rises, the less fuel pressure (rail
Only TAD650/660/750/760VE has a 42-pin connector. pressure) is obtained. So if a wire breaks full fuel flow
will be achieved.
P0015443
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30-2 Fault Tracing
MID 128, SID 70 Air inlet heater

driver #1

Fault code explanation: Faulty relay / Faulty relay circuit
CIU: None
Flash code
Value fault: None
Symptom: Fuse for shorting wire breaks.
Conditions for fault code: The voltage on pin B7 on the EMS 2 is higher than normal.
Possible reason: • Short circuit to battery voltage in sense wire.
Suitable action: 1 Check cable harness and connectors between B7 and the connection
at the heating element.

CIU: None
Flash code
Value fault: None
Symptom: Start problems in cold climate.
Conditions for fault code: The voltage on pin B7 on the EMS 2 is lower than normal.
Possible reason: • Broken preheat fuse if fuse is located between starter motor and pre-
heat relay.
• Open circuit in cable between starter motor and preheat relay.
• Short circuit to battery negative in sense wire.
Suitable action: 1 Check preheat fuse.
2 Check cable harness and connectors between B7 and the connection
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30-2 Fault Tracing

CIU: None
Flash code
Value fault: None
Symptom: Might get start problems in cold climate.
Possible reason: • Broken preheat fuse if fuse is located between preheat relay and heat-
ing element.
• An open circuit in sense wiring.
• Broken heating element.
Suitable action: 1 Check contact pressure in socket 7 in engine connector B.
2 Check cable harness and connectors between B7 and the connection
3 Check heating element.
In cold climate the intake air need too be preheated.
7 This is either done for GE engines by the preheater
25 1
A which is located in the inlet manifoldor or for VE
(+)57 2
engines by the glowplugs that are mounted in the cyl-
(+)60
inderhead. The preheat function is activated/deacti-
EMS2 vated by the engine control unit via the preheat relay.
P0015473 While the relay is not activated the potential on B25 is
A Preheat relay equal to battery voltage. When the preheat function is
B Connector B activated B25 alter its potential and the relay activates.
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.
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30-2 Fault Tracing
MID 128, SID 146 EGR Valve 1


Fault code explanation: SRA temperature above range.
CIU: None.
Symptom: Warning, red light if value >125 °C, engine derate 75% of full derate curve.
Possible reason: 1 EGR cooling limited.
2 EGR actuator failure.
Suitable action: 1 Check EGR cooling.
2 Check coolant leakage.
3 Check EGR actuator.

Fault code explanation: Incorrect value CAN bus..
CIU: None.
Symptom: Valve opens, low boost, low power, smoke.
Possible reason: 1 CAN-bus.
2 CAN-bus disturbance, no interruption.
3 Faulty EGR ECU.
Suitable action: 1 Check cable harness and connectors..
2 Check EGR ECU connectors (internal).
FMI 4 – Voltage below normal or shorted low

Fault code explanation: Short circuit to ground.
CIU: None.
Symptom: Actuator will attempt to maintain valve position or valve vill open resulting in
low boost, low power.
Possible reason: Short circuited to ground , supply voltage to EGR is below 10 V.
Suitable action: 1 Check cable harness and connectors.
2 Check battery voltage.
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30-2 Fault Tracing
FMI 7 – Mechanical system not responding properly

Fault code explanation: Mechanical failure.
CIU: None.
Symptom: Actuator motor effort temporary limited to prevent overheating.
Possible reason: SRA-position is not tracking command.
Suitable action: 1 Check cable harness and connectors.
2 Check mechanical parts.
3 Check supply voltage to EGR actuator.
FMI 12 – Faulty device or component

Fault code explanation: Faulty device.
CIU: None.
Symptom: Valve opens, low boost, low power, smoke.
Possible reason: • Internal failure.
• Actuator set to default position.
Suitable action: 1 Check / change the actuator.
FMI 13 – Calibration value out of range

Fault code explanation: Out of calibration.
CIU: None.
Symptom: None or possible low boost.
Possible reason: End position control (reference run) that is performed at every start has not
been approved.
Suitable action: 1 Check mechanical parts.
2 Check cable harness and connectors.
3 Check mechanical end position (internal).
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30-2 Fault Tracing
Circuit description
The SRA (Smart Remote Actuator) drives the linked
EGR valve into the position that is required by the
engine control unit to provide the optimum EGR rate.
It is connected to the J1939 CAN-bus and power sup-
ply from battery is provided when ignition on is active.
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30-2 Fault Tracing
MID 128, SID 211 Sensor Supply

Voltage #2 (+5V DC)

CIU: Flash code
Flash code
Value fault: None
Symptom: None
Conditions for fault code: The voltage exceeds the normal value or is short circuited to higher voltage
Possible reason: Short circuit between 5V supply voltage and battery voltage in EMS 2 con-
nector B.
Suitable action: 1 Check all 5V supply cables distributed by EMS 2 connector B. (see EMS
2 wiring diagram)

CIU: Flash code
Flash code
Value fault: None
Symptom: None
Possible reason: • Short circuit between the supply cables to the oil pressure sensor.
• Short circuit between the supply cables to the fuel pressure sensor.
Suitable action: 1 Check the sensor supply cables to oil pressure sensor.
2 Check the sensor supply cables to fuel pressure sensor.
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30-2 Fault Tracing
MID 128 / 144, SID 231 SAE J1939

data link

Fault code explanation: Communication fault J1939
CIU: Flash code
Flash code

Possible concurrent displayed • MID 128, SID 250 SAE J1708/J1587 data link, FMI 11
fault code:
• MID 128, PSID 201 Data link, MID144 page 113, FMI 9
Symptom: Engine can not be started or if engine is running it can only be stopped by
pushing the aux-stop.
Conditions for fault code: CAN communication is missing.
Possible reason: • The aux stop button has been activated.
• CAN H and CAN L short circuited to each other.
• 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.
Suitable action: 1 If the AUX stop button has been pushed the EMS2 needs to be shut-
down. Turn main switch off and let the system power down before turn-
ing the main switch on. Check if fault code has disappeared.
2 Check all data links between DCU/CIU and EMS2.
Measurements: • Checking the CAN bus cable page 136
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30-2 Fault Tracing
A (B51) Y/W 1 Cable description

B (B55) GR/Y 2 A CAN H - Data Link to Engine
C SB 3
D R 4 B CAN L - Data Link to Engine
E (A58) R/BL 5
F (A27) GR/SB 6 C Power supply
G (A34) W 7 D Power supply input
H (A33) W/SB 8
E Ignition
EMS2 DCU/CIU
P0015474 F Stop
G J1708A - Data Link to Engine
H J1708B - Data Link to Engine
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30-2 Fault Tracing
MID 128, SID 232 5 V supply


CIU: Flash code
Flash code
Value fault: None
Symptom: None
Conditions for fault code: The voltage exceeds the normal value or is short circuited to higher voltage
Possible reason: Short circuit between 5V supply voltage and battery voltage in EMS 2 con-
nector A.
Suitable action: 1 Check all 5V supply cables distributed by EMS 2 connector A. (see EMS
2 wiring diagram)

CIU: Flash code
Flash code
Value fault: None
Symptom: None
Possible reason: • Short circuit between the supply cables to the air inlet pressure sensor.
• Short circuit between the supply cables to the rail pressure sensor.
Suitable action: 1 Check the sensor supply cables to air inlet pressure sensor.
2 Check the sensor supply cables to rail pressure sensor.
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30-2 Fault Tracing
MID 128, SID 240 Program memory

FMI 11 – Unidentifiable error

Fault code explanation: Communication fault.
CIU: Flash code
Flash code
Value fault: None
Symptom: The engine can not be started.
Conditions for fault code: Checksum error.
Possible reason: • Downloading interrupted.
• Internal fault in the engine control unit.
Suitable action: 1 Reprogram the engine control unit.
2 Replace the engine control unit.
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30-2 Fault Tracing
MID 128 / MID 144, SID 250 SAE

J1708/J1587 data link

Fault code explanation: Communication fault J1587/J1708
CIU: None
Flash code
Value fault: None
Possible concurrent displayed • MID 128 / 144, SID 231 SAE J1939 data link page 100, FMI 2
fault code
Symptom: None
Conditions for fault code: Missing data on J1708/J1587 link.
Possible reason: AUX stop buttton has been activated.
Suitable action: 1 If the AUX stop button has been pushed the EMS2 needs to be shut-
down. Turn main switch off and let the system power down before turn-
ing the main switch on. Check if fault code has disappeared.
2 Check all data links between DCU/CIU and EMS2.
3 Check the contact pressure in socket 33 and 34 in the engine connector
A.
4 Check that the socket 22 and 37 in the CIU connector is undamaged.
A Y/W 1 Cable description

B GR/Y 2 A CAN H - Data Link to Engine
C SB 3
E R/BL 5
F GR/SB 6 C Power supply, 0 V
G W 7 D Power supply input
H W/SB 8
E Ignition
EMS2 a DCU/CIU
P0013534 F Stop
a Engine connector
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30-2 Fault Tracing
MID 128, SID 254 Controller 1

FMI 3 – RAM addressing failure

Fault code explanation: Faulty component
CIU: Flash code
Flash code
Symptom: The engine can not be started.
Suitable action: 1 Replace the engine control unit.
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30-2 Fault Tracing
MID 128, PSID 96 Rail pressure

system

Fault code explanation: Fault in rail pressure circuit
CIU: Flash code
Lamp status
FMI 0,12: Yellow lamp
FMI 1, 4, 7: Red lamp
Flash code
Value fault: None
Symptom: Engine derated: engine speed limitation (1100 rpm). Full fuel flow delivery.
Limp home with pressure relief valve opened.
Conditions for fault code: Rail pressure controller integral part too low.
Possible reason: • MPROP stuck open due to mechanical fault or an open circuit in
MPROP electrical wiring.
• An injector does not open.
Suitable action: 1 Check contact pressure in socket 12 and 16 in engine connector A.
2 Check MPROP cables and connectors. (see "Checking the solenoid in
the MPROP valve" under MID128, SID 42)
4 Change MPROP valve.
5 Check if an injector is faulty.
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30-2 Fault Tracing

CIU: Flash code
Lamp status
Flash code
Value fault: None
Symptom: Engine derated: engine speed limitation (1100 rpm). Fuel pressure limitation
(800 bar). Engine torque reduction.
Conditions for fault code: Rail pressure controller integral part too big. High pressure leakage detected.
Possible reason: • High pressure leakage.
• MPROP closed or partly closed or out of characteristic.
• Rail pressure release valve stuck open or unwanted opening.
• An injector is stuck open.
• Faulty high pressure pump.
Suitable action: 1 Check fuel pipes for leakage (high pressure pipes, suction pipes, return
pipes).
2 Check function of rail pressure sensor (see MID 128, PID 164).
3 Change the rail pressure release valve.
7 Check both high pressure pumps (see workshop manual Group 21-26).
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30-2 Fault Tracing

CIU: Flash code
Lamp status
Flash code
Value fault: None
(800 bar). Engine torque reduction. Engine shut off or difficult to start.
Conditions for fault code: Low rail pressure
Possible reason: • Low fuel level.
• Air gets into the fuel system.
• High pressure leakage.
• Low pressure leakage.
• Blocked fuel filter, pre- and fine filter.
Suitable action: 1 Check fuel level, hoses and fuel filter for leakage.
2 Check fuel pipes for leakage (high pressure pipes, suction pipes, return
pipes).
3 Change fuel filters, pre- and fine filter.
4 Check function of rail pressure sensor (see MID 128, PID 164).
9 Check both high pressure pumps (see workshop manual Group 21-26).
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30-2 Fault Tracing

CIU: Flash code
Lamp status
Flash code
Value fault: None
Conditions for fault code: Cylinder balancing exceeding upper threshold. Rail pressure controller inte-
gral part too big.
Possible reason: High pressure pipes rail to injector leakage, see SID1-6 (FMI 7) for info which
injector.
Suitable action: 1 Check for leakage in the high pressure system.
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30-2 Fault Tracing

CIU: Flash code
Lamp status
Flash code
Value fault: None
Conditions for fault code: Rail pressure too low. Rail pressure nominal value deviates positive from set
point value.
Possible reason: • Low fuel level.
• Air gets into the fuel system.
• High pressure leakage.
• Low pressure leakage.
• Blocked fuel filter, pre- and fine filter.
Suitable action: 1 Check fuel level, hoses and fuel filter for leakage.
2 Check fuel pipes for leakage (high pressure pipes, suction pipes, return
pipes).
3 Change fuel filters, pre- and fine filter.
4 Check function of rail pressure sensor. (see MID 128, PID 164)
9 Check both high pressure pumps.
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30-2 Fault Tracing
MID 128, PSID 97 Pressure Release

Valve

Fault code explanation: Leakage detected in pressure release valve
CIU: Flash code
Lamp status
FMI 0, 11, 14: Yellow lamp
FMI 7: Red lamp
Flash code
Value fault: None
Conditions for fault code: Leakage detected in pressure release valve, open mode.
Possible reason: • Rail pressure controller out of range.
• Faulty pressure release valve.
2 Change the pressure release valve.

Fault code explanation: Pressure release valve stuck close
CIU: Flash code
Lamp status
FMI 7: Red lamp
Flash code
Value fault: None
Symptom: Engine shut off after delay or engine derated. Engine derated: engine speed
limitation (1100 rpm). Fuel pressure limitation (800 bar). Engine torque reduc-
tion.
Conditions for fault code: Pressure release valve stuck close.
Possible reason: • An open circuit in one or both cables from EMS 2 to MPROP.
• Short circuit to battery negative in MPROP positive wire, pin 1 on
MPROP.
• Pressure release valve stuck close.
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30-2 Fault Tracing

Fault code explanation: Pressure release valve open
CIU: Flash code
Lamp status
FMI 7: Red lamp
Flash code
Value fault: None
Conditions for fault code: High rail pressure when pressure release valve is open.
Possible reason: • Rail pressure controller out of range.
• Pressure release valve stuck close or out of characteristic.

Fault code explanation: Pressure release valve open
CIU: Flash code
Lamp status
FMI 7: Red lamp
Flash code
Value fault: None
Symptom: Engine derated: engine speed limitation (1100 rpm). Engine torque reduction.
Full fuel flow delivery. Limp home with pressure release valve opened.
Conditions for fault code: Pressure release valve stuck open.
Possible reason: • Blocked fuel return line.
• An open circuit in one or both cables from EMS 2 to MPROP.
• Short circuit to battery negative in MPROP negative cable, pin 2 on
MPROP.
• MPROP stuck open.
• Faulty pressure release valve.
Suitable action: 1 Check fuel return line.
2 Check contact pressure in socket 12 and 16 in engine connector A. Also
3 Check cable harness and connector between EMS 2 and MPROP.
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30-2 Fault Tracing
MID 128, PSID 201 Data link, MID144

FMI 9 – Abnormal updating rate

Fault code explanation: Communication error.
CIU: None
Flash code
Value fault: None
Possible concurrent displayed • MID 128 / 144, SID 231 SAE J1939 data link page 100, FMI 2
fault code
Symptom: None.
Conditions for fault code: No communication with the engine control unit.
Possible reason: • 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.
Suitable action: 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.
Measurements: • Checking the CAN bus cable page 137
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30-2 Fault Tracing
A (B51) Y/W 1 Component description

B (B55) GR/Y 2 A CAN H - Data Link to Engine
C SB 3
E (A58) R/BL 5
F (A27) GR/SB 6 C Power supply
G (A34) W 7 D Power supply input
H (A33) W/SB 8
E Ignition
EMS2 DCU/CIU
P0015474 F Stop
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30-2 Fault Tracing
Measurements
Checking the preheat relay
Tools:
9990014 Break-out cable
9998699 Break-out box
88890074 Multimeter
NOTICE! If any of the measurements shows an abnor-

mal value, check the wiring to and from the engine
control unit and the preheat relay.
Checking the wiring:

1 Cut the current with the main switch.
2 Remove connector B from the EMS2.
3 Connect the B connector to break-out cable
9990014 with break-out box 9998699.
4 Use multimeter 88890074 to do resistance meas-
urement.
Measurement points Nominal value

25 (relay activation) - one of the pre- R ≈ 0 Ω
heat connectors
57 (relay +) - one of the preheat R≈0Ω
connectors
60 (relay +) - one of the preheat R≈0Ω
connectors
Checking supply cable, fuel sensor

Tools:
88890074 Multimeter
1 NOTICE! Turn ignition off.

2 Disconnect the connector from the sensor.
3 Connect break-out cable 885675 to the cable har-
ness connector to the engine control unit.
4 Use multimeter 88890074 for voltage measure-
ment.
5 Turn ignition on.

1–4 U≈5V
p0013473
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30-2 Fault Tracing
Checking negative cable, fuel

sensor
Tools:
88890074 Multimeter

urement against the engine control unit.

4 – Battery negative R≈0Ω
75
8856 885675
5
4
3
2
4
1
P0010786
116 47702487 11-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking signal cable, fuel sensor

Tools:
88890074 Multimeter
• NOTICE! Cut the current with the main switch.

• Disconnect the connector from the sensor
• Connect break-out cable 885675 to the cable har-
• Use multimeter 88890074 to do resistance meas-

4–2 R≈ 80-120 kΩ
NOTICE! Measurement is done to eliminate short cir-

cuiting or breaks in the cable to the engine control unit.
Checking fuel pressure sensor

V Tools:
88890074 Multimeter

3 Connect break-out cable 885675 between the sen-
sor and the engine control unit.
ment.
5 Turn ignition on.

4–2 U ≈ 0,5 V*
* At normal atmospheric pressure.
75
8856
5
4
3
2
4
1
2
p0010784
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30-2 Fault Tracing
Checking supply cable, water in fuel

switch
Tools:
88890074 Multimeter

2 Disconnect the connector from the switch.
3 Use multimeter 88890074 to do a voltage meas-
urement.
4 NOTICE! Turn ignition on.

Yellow conductor – U ≈ Battery voltage x 0.8
Black conductor
Checking negative cable, water in

fuel switch
Tools:
88890074 Multimeter


Black conductor – R≈0Ω
Battery negative
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30-2 Fault Tracing
Checking water in fuel switch

Tools:
88890074 Multimeter

2 Disconnect the connector to the water in fuel
switch.
3 Remove the water in fuel switch.
4 Use multimeter 88890074 to do a resistance meas-
urement towards the switch.

1-2, Switch immersed in water R≈0Ω
1-2, Switch immersed in fuel R≈∞Ω
P0010785
Checking supply cable, oil pressure

sensor
Tools:
88890074 Multimeter

interface.

2 Remove the connector from the sensor.
ment.

1–3 U≈5V
75
8856
5
4
3
2
1
3
1
P0010787
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30-2 Fault Tracing
Checking negative cable, oil

pressure sensor
Tools:
88890074 Multimeter


75
8856
885675
5
4
3
2
1
3
P0010788
Checking signal cable, oil pressure

sensor
Tools:
88890074 Multimeter


2–3 R ≈ 80 – 120 kΩ

75
8856
885675
5
4
3
2
1
3
2
P0015362
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30-2 Fault Tracing
Checking oil pressure sensor

Tools:
88890074 Multimeter

ment.
5 Turn ignition on.

2–3 U ≈ 0.5 V*
75
8856
5
4
3
2
1
3
2
P0015363
Checking signal cable, inlet

manifold temperature sensor
Tools:
88890074 Multimeter

interface.

ment.
5 Turn ignition on.

1–2 U≈5V
75
8856 885675
5
4
3
2
1
P0015365 2
1
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30-2 Fault Tracing
Checking negative cable, inlet

manifold pressure/temperature
sensor
Tools:
88890074 Multimeter


75
8856
885675
5
4
3
2
1
P0015364 1
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30-2 Fault Tracing
Checking sensor cable, inlet

manifold temperature sensor
Tools:
88890074 Multimeter
Check for open circuit or short circuit:

4 Remove connector A from the engine control unit.
urement against the engine control unit connector
A.

2 (885675)– 47 (EMS 2, conn.A) R ≈ 0 Ω
2 (885675) – 11 (EMS 2, conn.A) R ≈ ∞ Ω
75
8856 1 (885675) – 47 (EMS 2, conn.A) R ≈ ∞ Ω
5
4
3
2
1 (885675) – 11 (EMS 2, conn.A) R ≈ 0 Ω
1
1 885675
75
8856
5
4
3
2
1
2
P0015366
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30-2 Fault Tracing
Checking inlet manifold

temperature sensor
Tools:
88890074 Multimeter

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

1–2 R ≈ 9426 Ω
+/- 470 Ω (vid -10° C)
1–2 R ≈ 5896 Ω
+/- 332 Ω (vid 0° C)
1–2 R ≈ 2511 Ω
+/- 109 Ω (vid 20° C)
1–2 R ≈ 1200 Ω
75 +/- 47 Ω (vid 40° C)
8856 885675
5
1–2 R ≈ 612 Ω
4
3
2
+/- 22 Ω (vid 60° C)
1
2
P0013486 1 1–2 R ≈ 329 Ω
+/- 11 Ω (vid 80° C)
1–2 R ≈ 186 Ω
+/- 5 Ω (vid 100° C)
1–2 R ≈ 110 Ω
Checking supply cable, inlet

manifold pressure sensor
V Tools:
88890074 Multimeter

2 Remove the connector from the sensor. Connect
break-out cable 885675 between the sensor and
engine control unit.
ment.
4 Turn ignition on.

1–3 U≈5V
75
8856
5
4
3
2
1
3
1
P0013487
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30-2 Fault Tracing
Checking signal cable, inlet

manifold pressure sensor
Tools:
88890074 Multimeter


4–1 R ≈ 80 – 120 k Ω
75
8856
885675 cuiting or breaks in the cable to the engine control unit.
5
4
3
2
4
1
P0013488 1
Checking air inlet pressure sensor

Tools:
88890074 Multimeter

ment.
5 Turn ignition on.
Measurement Nominal value

points
1–4 U ≈ 1,1 V (at normal
atmospheric pressure)
4
P0013489
1
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30-2 Fault Tracing
Checking supply cable, coolant

level switch
Tools:
88890074 Multimeter

3 If grey switch: Connect break-out cable 885675 to
the cable harness connector to the engine control
unit.
ment.

1–2 U ≈ Battery voltage x 0.8
Checking negative cable, coolant

level switch
Tools:
88890074 Multimeter

3 If grey switch: Connect break-out cable 885675 to
the cable harness connector to the engine control
unit.

2 – Battery negative R≈ 0 Ω
P0015371
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30-2 Fault Tracing
Checking coolant level switch

Tools:
88890074 Multimeter
NOTICE! The coolant level switch can be removed

without having to drain the coolant.
Checking black coolant switch

1 Undo the connector and remove the switch from the
expansion tank.
urement against the switch.
Blue – Black R≈∞Ω
3 Move a magnet along the switch and observe the

resistance value. The resistance should drop to
approx. 0 Ohm.

Blue – Black R≈0Ω
Checking grey coolant switch

1 Undo the connector and remove the level switch
from the expansion tank.
2 Connect break-out cable 885675 to the switch.
urement against the switch.
Measurement points- Nominal value
Move a magnet along the
switch and observe the
resistance value
1–2 R≈0Ω
4 Move a magnet along the switch and observe the

resistance value. The resistance should be ∞ Ohm.

1–2 R≈∞Ω
75
8856 885675
5
4
3
2
1
2
P0015373 1
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30-2 Fault Tracing
Checking starter motor relay coil

Tools:
88890074 Multimeter

2 Remove one of the wires to the starter motor relay.
3 Use multimeter 88890074 to measure the resist-
ance in the coil.

Relay connectors R ≈ 9-15 Ω
P0015382
Checking starter motor relay

voltage supply
V Tools:
88890074 Multimeter
1 Turn ignition off.

2 Connect multimeter 88890074 to do voltage meas-
urement over the starter motor relay.
3 Turn ignition on.
Relay connectors V≈0V
4 Push start button.

Relay connectors V ≈ Battery Voltage
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30-2 Fault Tracing
P0015383
Checking the wiring

Between EMS2 and IEGR
If any of the measurements shows an abnormal value,

check the wiring to and from the engine interface.
2 Remove the connector to the IEGR solenoid.
3 Remove connector B from the EMS2.
4 Connect the B connector to break-out cable
9990014 with break-out box 9998699.
urement.

30 (IEGR signal) - 2 (IEGR con- R≈0Ω
nector)
57, 60 (relay +) - 1 (IEGR con- R≈0Ω
nector)
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30-2 Fault Tracing
Checking IEGR coil

Tools:
88890074 Multimeter

2 Remove the connector from the IEGR solenoid.
urement.

1-2 R ≈ 28-42 Ω
P0015376
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 V power supply to the IEGR electrical
connection. The solenoid should now make a click
when altering its position.
LTS
VO
P0015377
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30-2 Fault Tracing
Checking the injectors

Tools:
88890074 Multimeter

interface.

2 Remove both wires that are connected to the injec-
tor that is to be measured.
3 Remove connector A from the EMS2.
urement between connector A from the EMS 2 to
the loosened wires from the injector. See circuit
description which pin in the connector A to measure
from.
P0015378
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30-2 Fault Tracing
Checking camshaft sensor wiring

Tools:
88890074 Multimeter

break-out cable 885675 to the connector.
urement from the sensor connector to connector A
to verify that neither of the wires are broken or short
circuited.
Measurement points Nominal

value
1 (sensor conn.) – 46 (conn. A) R≈0Ω
1 (sensor conn.) – 2 (sensor conn.) R≈∞Ω
75
8856
5
IMPORTANT!
4
3
2
1
Be very careful when measuring inside the connector,

1 885675 to ensure that no pin is damaged.
75
8856
5
4
3
2
1
P0015379
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30-2 Fault Tracing
Checking camshaft sensor

Tools:
88890074 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 break-out 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.
4 Use multimeter 88890074 for resistance measure-
ment.
885675
2
1 1–2 R ≈ 3,5 kΩ at 20 °C (68 °F)
NOTICE! The measurement must exclude short

circuit or open circuit to the engine control unit.
5 Use multimeter 88890074 for a AC voltage meas-
urement.
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.
2
1
P0015380
47702487 11-2012 © AB VOLVO PENTA 133

30-2 Fault Tracing
Checking crankshaft sensor wiring

Tools:
88890074 Multimeter

break-out cable 885675 to the connector.
urement from the sensor connector to connector A
to verify that neither of the wires are broken or short
circuited.
Measurement points Nominal

value
1 (sensor conn.) – 2 (sensor conn.) R≈∞Ω
75
8856
5
IMPORTANT!
4
3
2
1
Be very careful when measuring inside the connector,

1 885675 to ensure that no pin is damaged.
75
8856
5
4
3
2
1
P0015379
134 47702487 11-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking crankshaft sensor

Tools:
88890074 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 break-out cable 885675 to sensor.
4 Use multimeter 88890074 for resistance measure-
ment.
885675
2
1 1–2 R ≈ 0,9 kΩ at 20 °C (68 °F)
NOTICE! The measurement must exclude short

circuit or open circuit to the engine control unit.
5 Use multimeter 88890074 for a AC voltage meas-
urement.
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.
2
1
P0015380
47702487 11-2012 © AB VOLVO PENTA 135

30-2 Fault Tracing
Checking the CAN bus cable

Communication fault J1939
Tools:
88890074 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.
urement towards the EMS 2.

in the engine connector
at the DCU
1–2 U ≈ 60 Ω
or

in the CIU connector
11–12 U ≈ 60 Ω
NOTICE! Even if the measured value equals the nom-

inal value the data bus cable could be faulty due to
short circuit between a data bus cable and another
cable in the harness.
1 Connect break-out cable 9990014 with break-out

box 9998699 between the EMS2 connector B and
the engine cable harness.
urement.
3 Turn ignition on.
Measurement points in the Nominal value

measurebox
B51 (CAN H) – B58 (B-) U ≈ 2.3–4.0 V
B55 (CAN L) – B58 (B-) U ≈ 1.0–2.5 V
NOTICE! The voltage value fluctuates. If it is static it

could indicate an open circuit.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.
136 47702487 11-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking the CAN bus cable

Communication error
Tools:
88890074 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.
urement towards the EMS 2.

in the engine connector
at the DCU
1–2 U ≈ 60 Ω
or

in the CIU connector
11–12 U ≈ 60 Ω

1 Connect break-out cable 88890016 with break-out

box 9998699 between the EMS 2 and the CIU/
DCU.
urement.

in the measurebox
16 – 17 (between CAN U ≈ 2.3 V – 2.7 V
bus)

47702487 11-2012 © AB VOLVO PENTA 137

30-2 Fault Tracing
Checking negative cable, coolant

temperature sensor
Tools:
88890074 Multimeter

interface.

urement towards the engine control unit.

75
8856
885675
5
4
3
2
1
P0015368 1
138 47702487 11-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking signal cable, coolant

temperature sensor
Tools:
88890074 Multimeter
1 Turn ignition on.

ment.

1–2 U≈5V
75
8856
885675
5
4
3
2
1
P0015367 2
1
47702487 11-2012 © AB VOLVO PENTA 139

30-2 Fault Tracing
Checking sensor cable, coolant

temperature sensor
Tools:
88890074 Multimeter
Check for open circuit or short circuit

4 Remove connector B from the engine control unit.
B.

2 (885675) – 27 (EMS 2, conn.B) R ≈ 0 Ω
2 (885675) – 18 (EMS 2, conn.B) R ≈ ∞ Ω
75
8856 1 (885675) – 27 (EMS 2, conn.B) R ≈ ∞ Ω
5
4
3
2
1 (885675) – 18 (EMS 2, conn.B) R ≈ 0 Ω
1
2 885675
75
8856
5
4
3
2
1
1
P0015369
140 47702487 11-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking coolant temperature

sensor
Tools:
88890074 Multimeter

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

1–2 R ≈ 9397 Ω
+/- 755 Ω (at -10° C)
1–2 R ≈ 5896 Ω
+/- 430 Ω (at 0° C)
1–2 R ≈ 2500 Ω
+/- 148 Ω (at 20° C)
1–2 R ≈ 1175 Ω
8856
75 +/- 56 Ω (at 40° C)
5
4
1–2 R ≈ 596 Ω
3
2
1
+/- 22 Ω (at 60° C)

1 885675
P0015370 1–2 R ≈ 323 Ω
+/- 10 Ω (at 80° C)
1–2 R ≈ 186 Ω
+/- 5 Ω (at 100° C)
1–2 R ≈ 113 Ω
+/- 4 Ω (at 120° C)
47702487 11-2012 © AB VOLVO PENTA 141

30-2 Fault Tracing
Checking supply cable, rail

pressure sensor
interface.

ment.
5 Turn ignition on.

1–3 U≈5V
75
8856
5
4
3
2
1
3
1
P0010787
Checking negative cable, rail

pressure sensor
Tools:
88890074 Multimeter


1 – Battery negative R ≈0 Ω
75
8856 885675
5
4
3
2
1
P0015374 1
142 47702487 11-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking signal cable, rail pressure

sensor
Tools:
88890074 Multimeter


1-2 R ≈ 4.0–5.0 kΩ

75
8856
885675
5
4
3
2
1
2
P0015375
1
47702487 11-2012 © AB VOLVO PENTA 143

30-2 Fault Tracing
Checking injection control pressure

sensor
V Tools:
88890074 Multimeter

ment.
5 Turn ignition on.

1-2 U ≈ 0,5 V*
75
8856
5
4
3
2
1
2
1
P0013317
144 47702487 11-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking the wiring to the MPROP

valve
Tools:
88890074 Multimeter

interface.

2 Remove the connector to the MPROP.
A.

2 (885675) – 16 (EMS 2, conn. A) R ≈ 0 Ω
2 (885675) – 12 (EMS 2, conn. A) R ≈ ∞ Ω
1 (885675) – 16 (EMS 2, conn. A) R ≈ ∞ Ω
75
8856 1 (885675) – 12 (EMS 2, conn. A) R ≈ 0 Ω
5
4
3
2
1
2 885675
75
8856
5
4
3
2
1
P0015384
47702487 11-2012 © AB VOLVO PENTA 145

30-2 Fault Tracing
Checking the solenoid in the

MPROP valve
Tools:
88890074 Multimeter

2 Remove the connector from the MPROP valve.
Connect break-out cable 885675 to the valve.
3 Use multimeter 88890074 to check the resistance
in the solenoid in the MPROP valve.
NOTICE! Measurement is done to eliminate short
circuiting or breaks in the MPROP valve.

1–2 R ≈ 2–4 Ω at 20 °C (68 °F)
146 47702487 11-2012 © AB VOLVO PENTA

30-2 Fault Tracing
VODIA Log Parameters

Logging throttle signal with Vodia
To verify the throttle signal on the J1587 bus do as fol-
low:
1 Choose “Log test” under the “Service and mainte-
nance” meny.
2 Choose “MID 128, Accelerator Pedal Position” and
“MID 144, Throttle Calibrated Position” and press
play.
3 Verify that booth throttle values displayed in per-
centage by Vodia changes simultaneous while
moving the throttle.
47702487 11-2012 © AB VOLVO PENTA 147

37-0 Wiring Diagrams

TAD650, 660, 750, 760 VE
1
R/Y 1,5
5 2
R/BL 1,5
2 3
R/BL 1,5
3 11 1 31
M
30
Y/SB
4 12 2
26 25
SB
7 30 1
6 24 GR/W 2
GN/BL
27
12 17
R
10 10 1 P2
9 16 SB 4
28
SB
8 27
R
11 33 1
BL/OR 3
13 26 2P
SB
29
14 28
BN/OR
23 29
R R3 2
16 22
1 SB
20 23 GR/GN
4P
30
19 25 GR/W
R
17 32 R 3
SB SB
15 31 1 P2
31
R/Y 1
19
18 OR
20 2
32
VO/SB 0,75
15 1
21 GR/SB 0,75
21 2
3
n
1 33
14
OR/SB 0,75 1
GR/SB 0,75
22 13 2
3
n
9
34
34 W 2,5
(11)
W 1,0
35
CYL. A1 (11)
W 1,0
36
CYL. A2
(11)
W 1,0
37
CYL. A3
24 (11)
W 1,0
39
CYL. 4 (11)
W 1,0
40
CYL. 5 (11)
W 1,0
41
CYL. 6
W 2,5
42
P0015452
148 47702487 11-2012 © AB VOLVO PENTA

Description TAD650, 660, 750, 760 VE
1 Connector (X17) Cable colors

BL = Blue
2 Start Relay, Supply
LBL = Light blue
3 Internal EGR, Supply BN = Brown
LBN = Light brown
4 Internal EGR
GN = Green
5 Start Relay GR = Gray
OR = Orange
6 Coolant temperature
P = Pink
7 Coolant temperature, Ground R = Red
SB = Black
8 Oil pressure, Ground
VO = Purple
9 Fuel Pressure, Ground W = White
Y = Yellow
10 Fuel Pressure, Supply
11 Oil Pressure, Supply Cable cross section = 0.75 mm2 unless otherwise
stated.
12 Fuel Pressure
13 Oil pressure
14 Air inlet pressure/temperature, Ground
15 Rail pressure, Ground
16 Air inlet pressure/temperature, Supply
17 Rail pressure, Supply
18 MPROP
19 Rail pressure
20 Air inlet pressure
21 Speed sensor, Crankshaft
22 Speed sensor, Camshaft
23 Inlet manifold temperature
24 Injectors
25 Start motor and prestart relay
26 Internal EGR, Sensor
27 Coolant temperature, Sensor
28 Fuel Pressure, Sensor
29 Oil pressure, Sensor
30 Air inlet pressure/temperature, Sensor
31 Rail pressure, Sensor
32 MPROP
47702487 11-2012 © AB VOLVO PENTA 149

31
29 32 33
27 28 30
47702487 11-2012 © AB VOLVO PENTA

A B
L
25 26 CAN2 H
(7)
2 1 1 2 1 2 3 4 5 6 7 8
W/SB
GR/Y
SB 2,5
R/BL 1,5
GR/SB
R 2,5
Y/W
W
35
86
1 R/BL
34 Y/SB 1 85
R/BL 1,5 2 87
2 3 R/BL 1,5 2 1 30
3 11 R/BL 1,5 R 1,5 4
TAD650, 660, 750, 760 VE
R 1,5 3
4 12 Y/SB 40
5
5 2 R/Y
6 24 GR/W
SB
Y
7 30 SB 1 2 3 4 5 6 7
8 27 SB
SB
Y
9 16 SB R 1
W/SB
10 R 2
10 39 W 5
11 33 R
B SB 3
SB
12 17 GN/BL
CAN j1939
C 4
13 26 BL/OR
CAN 2
6
36
BN/OR
GN/SB
BL/OR
GN/BL
BL/GR
GN/W
GR/W
BL/W
GR/Y
Y/SB
R/BL
R/BL
LBN
Y/W
R/Y
OR
SB
SB
SB
SB
SB
R
SB 2,5
R 2,5
41 3 4 11 16 17 18 27 29 30 8 10 23 7 25 57 60 52 56 51 55 58 59 61
h l h l
1
3
(6) B 42 2 1
2
14 28 SB 4
A 43 B A
15 31 SB 31 11 7 16 12 19 22 37 38 45 46 47 36 40 44 48 52 56 59 60 8 33 34 27 58 57
GR/GN
GR/SB
GR/SB
OR/SB
W 1,0
W 1,0
W 1,0
W 1,0
W 1,0
W 1,0
GR/SB
SB 1,5
W 2,5
R 1,5
GR/OR
R/Y
BN/OR
W
W/SB
VO/SB
GR/W
R/BL
SB
Y/SB
OR
W 2,5
16 22 R
17 32 R 37
20 OR
18
19 R/Y
MAIN RELAY HOLD
19 25 GR/W
20 23 GR/GN
SB 2,5
R 2,5
21 GR/SB
21 15 VO/SB
14 OR/SB
22
13 GR/SB
23 29 BN/OR START
41 W 1,0
38
40 W 1,0
39 W 1,0
37 W 1,0
24 36 W 1,0
P0015451
35 W 1,0
34 W 2,5
150
42 W 2,5
Description TAD650, 660, 750, 760 VE
1 Connector (X17) Cable colors

2 Start Relay, Supply BL = Blue
3 Internal EGR, Supply LBL = Light blue
BN = Brown
4 Internal EGR
LBN = Light brown
5 Start Relay GN = Green
6 Coolant temperature GR = Gray
7 Coolant temperature, Ground OR = Orange
8 Oil pressure, Ground P = Pink
9 Fuel Pressure, Ground R = Red
SB = Black
10 Fuel Pressure, Supply
VO = Purple
11 Oil pressure, Supply W = White
12 Fuel Pressure Y = Yellow
13 Oil pressure
14 Air inlet pressure/temperature, Ground Cable cross section = 0.75 mm2 unless otherwise
stated.
15 Rail pressure, Ground
16 Air inlet pressure/temperature, Supply
17 Rail pressure, Supply
18 MPROP
19 Rail pressure
20 Air inlet pressure
23 Inlet manifold temperature
24 Injectors
25 Preheat, Sensor
26 Preheat relay
27 Preheat, Supply
28 J1939 CAN bus
29 Battery negative
30 Battery plus
31 Ignition
32 Stop
33 J1587/1708 (bus)
34 Extra Stop (Aux stop)
35 Main relay
36 8-pin connector engine interface
37 Main fuse 10A
38 Battery (24V)
39 Coolant Level
40 Water in Fuel
41 Oil level/temperature
42 Connector A, Control unit EMS 2
43 Connector B, Control unit EMS 2
47702487 11-2012 © AB VOLVO PENTA 151

47702487 11-2012 © AB VOLVO PENTA
7
BATT.+
11 CAN 1708
J1939 BATT.- SWITCHED J1587
1 2 H L BATT.+ STOP A B 10
CAN2
1 2 3 4 5 6 7 8 1 2 3 4 5 6
W/SB
R/BL1,5
SB
W
R
GN/W
SB2,5
W/SB
GR/Y
R2,5
Y/W
W
23
5
6 86
Y/SB 85
1
2 1 R/BL1,5 R/BL1,5 87
2
SB
30
Y
R1,5
12 3 45 6 7 4
SB
R 3
5
24 8 21
4 SB 2 SB
2P 1 R 2 1
SB 1
TAD734 GE
25 R/BL
4 SB R/BL1,0
1 R
2 P
BN/OR1,0
R/BL1,5
R/BL1,5
BL/GR
BL/OR
GN/BL
OR1,0
SB1,0
SB1,5
SB1,5
SB1,0
SB1,5
GR/W
BL/W
GR/Y
R1,0
Y/W
LBN
30
R/Y
Y
11 16 17 18 27 23 10 8 52 56 29 25 57 60 7 58 59 61 51 55
CONNECTORB h l h l
R2,5
SB2,5
CONNECTORA
B A
11 7 47 22 19 45 46 37 38 12 16 36 40 44 48 52 56 59 60 8 33 34 27 58 57
- +
GN/W
R/BL1,5
SB1,5
GR/GN
W/SB
W2,5
W2,5
BN/OR
SB1,0
Y/SB
OR/SB
GR/SB
GR/SB
VO/SB
GR/W
W1,0
W1,0
R1,0
W1,0
W1,0
W1,0
W1,0
R/Y
OR
W
33
9 7 5 4 2
R 3
2
SB 1
P4
MAINRELAYHOLD
3
2
2 CYL.1 1
1
OR1,0
P 17 19
26 1 2 2 1
n n
R/BL1,5
3 1 2 18 R25
2 CYL.2 1
32
R2,5
R/W
R/Y
20
SB2,5
13 14
12 3 45 SB25
B+ B-
1 CYL.3 2 SB25
34 4 G M 30
31
3
7 5 4 2 R25
2
SCHPOS
2 CYL.4 1
1
1 CYL.5 2
P0015453
16
152
1 CYL.6 2
Description TAD734GE
1 Battery Cable colors

BL = Blue
2 Main switch
LBL = Light blue
3 Starter motor BN = Brown
LBN = Light brown
4 Alternator
GN = Green
5 Main relay GR = Grey
OR = Orange
6 Aux stop switch
P = Pink
7 Connector, Engine interface R = Red
SB = Black
8 Sensor, Coolant temperature
VO = Purple
9 Sensor, temperature/pressure, Charge Air W = White
Y = Yellow
10 Diagnosis connector, J1587
11 Connector, Development tool Cable cross section = 0.75 mm2 unless otherwise
stated.
12
13 Sensor, camshaft
14 Sensor, crankshaft
15
16 Injector
17 Relay, Preheater
18 Fuse
19 Fuse, 10A
20 Preheater
21 Switch, Coolant Level
22
23 Switch, Water in Fuel
26 Fuel/Rail Pressure
27
28
29
30 Control unit EMS 2
31
32 MPROP
33 Connector injectors
34 Connector injectors
47702487 11-2012 © AB VOLVO PENTA 153

TAD550-551 GE, TAD750-754 GE
P0015454
154 47702487 11-2012 © AB VOLVO PENTA

Description TAD550-551 GE, TAD750-754

GE

BL = Blue
2 Main switch
LBL = Light blue
LBN = Light brown
4 Alternator
GN = Green
5 Main relay GR = Grey
OR = Orange
6 Aux stop switch
P = Pink
7 Connector, Engine interface R = Red
SB = Black
VO = Purple
9 Sensor, temperature/pressure, Charge Air W = White
Y = Yellow
10 Diagnosis connector, J1587
11 Cable cross section = 0.75 mm2 unless otherwise
stated.
12
13 Sensor, camshaft
14 Sensor, crankshaft
15
16 Injector
17 Relay, Preheater
18 Fuse
19 Fuse, 10 A
20 Preheater
22
23 Switch, Water in Fuel
26 Fuel/Rail Pressure
27
28
29
30 Control unit EMS 2
31
32 MPROP
33 Connector, Preheat relay
34 External EGR
35 Fuse 30A
36
37
38
39 Electric fan
47702487 11-2012 © AB VOLVO PENTA 155

CIU
1 2 3 4 5 6 7 8 23
30
R/BL 1,5
GR/Y
R 2,5
W/SB
Y/W
SB 2,5 SB 1,5
W
14
SB 2,5
27
R 2,5 1
R 1,5
R/BL 1,5 R/BL 1,5
28
W
22
W/SB
37
R/BL 1,5
Y/W
SB 2,5
GR/Y
R 2,5
Y/W
12
W/SB
W
11 GR/Y
GN/Y
30 1 2 3 4 5 6 7 8 27
2
SB
GN/SB
2
1 2 3 4 5 6 7 8
3
GN/OR 26
24
29 R/W R
R/GR 8 SB SB
1
R/BN 9 R/SB
15
10
R/BL
R/Y
R/BL
R/BL
35
R/BL
SB
VO 11
41 7
SB
12
SB
P
SB
SB
16
25 3
R SB - 7
10 BN RPM/M + SB
R/SB R/SB
13
SB
4
33 GR/SB - P + 7
G SB
R/SB
LBN
SB
21
5
26 W/BL 13 R - C
+ 7
R/SB G
Y
20 6
BL/Y 14 R - C +
40
R/SB G
LBN
34
W/BN 15 R
9
W/GN 16
25
39 BL/OR 17
36 P/SB 18
7 VO/W 19
38 GL 20
R/GN 21
24
OR 22
17
R/SB 29
19
W/GL 28 1
SB
2
Y/BL R
8 3
P0014020
156 47702487 11-2012 © AB VOLVO PENTA

Description CIU
1 Key switch (15+) Cable colors

BL = Blue
2 Rpm-potentiometer
LBL = Light blue
3 Tachometer (code 14) BN = Brown
LBN = Light brown
4 Oil pressure, Instrument
GN = Green
5 Oil temperature, Instrument GR = Gray
OR = Orange
6 Coolant temperature, Instrument
P = Pink
7 Instrument illumination R = Red
SB = Black
8 Idling contact, two-way
VO = Purple
9 1500 / 1800 rpm switch, two-way W = White
Y = Yellow
10 Starter contact, spring biased
11 Stop switch, spring biased Cable cross section = 0.75 mm2 unless otherwise
stated.
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 Horn
20 Operation indicator
21 Preheating indication
22 Preheating contact
24 Governor switch
25 Battery Voltage Alarms
26 Termination resistance 120 Ohm
28 Contact, engine protection override
29 Easy Link connector block
30 Control Interface Unit (CIU)
47702487 11-2012 © AB VOLVO PENTA 157

DCU
1 2 3 4 5 6 7 8 8
SB 2,5
BL 2,5
11
W/SB
GR/Y
R 2,5
Y/W
W
R/BL 1,5
1
Y/W
2
GR/W
SB 2,5
3
R 2,5
4
R/BL 2,5
5
6
BL 2,5
7
W
8 W/SB
R/BL 1,5
SB 2,5
BL 2,5
W/SB
3
GR/Y
R 2,5
Y/W
W
1 1
1
VO 1 2 3 4 5 6 7 8 9
D 2 4
R/Y
C 2 1 2 3 4 5 6 7 8 10
U SB/Y
3
R/BL
4 5
1
Y
5 2
3
SB
6
GN/R
7
GN/Y
8 6
GN/SB
9
7
SB/VO
10
11
SB/GR
12
SB/W
P0014021
Cable colors
1 Stop contact
BL = Blue
2 Start contact LBL = Light blue
BN = Brown
3 1-pin connector
LBN = Light brown
4 Horn, buzzer alarm GN = Green
GR = Gray
5 Easy Link connector
OR = Orange
6 Rpm-potentiometer P = Pink
R = Red
7 Indicator engine operation
SB = Black
8 8-pin connector engine interface VO = Purple
W = White
Y = Yellow
10 Termination resistance 120 Ohm
Cable cross section = 0.75 mm2 unless otherwise
11 Display Control unit (DCU)
stated.
158 47702487 11-2012 © AB VOLVO PENTA

BATT.+
SWITCHED CAN BATT.+ 1708
CAN 1708 J1939 BATT.- SWITCHED J1587 BATT.+
J1939 J1587
HL AB
159
BATT.+ STOP BATT.-
HL AB 10
1 2 3 4 5 6 34 7 1 2 3 4 5 6 7 8 1 2 3 4 5 6 2 1 36
W/SB
Y/GR
BN/P
R/BL 1,5
SB 4
R/BL 1,5
CAN 2
R4
GN/SB
SB
SB 2,5
W
W/SB
R
GR/Y
R 2,5
Y/W
W
W/SB
Wiring Diagram TAD569(
R/BL 1 W
5
86
23 Y/SB
1
85
2 1 R/BL 1,5 R/BL 1,5 87
2
GR/OR
SB
30
4 6 R 1,5
Y
SB 2 4
3 1234567
1 R
3
SB
Y
38 5
37 24 21 CAN 3
SB 2,5
4M
R
4
SB 8 SB
2 SB 2
3
1 2P 1R 2 1
P5 SB 1
θ
2
SB SB
4 1 θ R/BL 1,0
R
1
2P 11
BN/OR 1,0
25
R/BL 1,5
R/BL 1,5
R/W 1,0
GN/SB
OR 1,0
BL/OR
GN/BL
BL/GN
BN 1,0
BL/GR
SB 1,0
SB 1,0
SB 1,5
SB 1,5
SB 1,5
GR/W
GN/W
BL/W
Y/GR
GR/Y
R 1,0
BN/P
LBN
Y/W
30
R/Y
GR
VO
BL
Y
1 5 24 11 16 17 18 31 27 3 4 49 23 10 8 52 56 22 21 29 25 37 57 60 7 58 59 61 51 55
h l h l h l
CONNECTOR B
R 2,5
CONNECTOR A BA
31 11 7 47 22 19 35 39 45 46 37 38 12 16 48 40 36 56 59 60 8 33 34 27 58 57
- +
GR/GN
GN
Y/SB
SB 1,0
R 1,0
OR/SB
GR/SB
GR/SB
VO/SB
W 1,0
W 1,0
W 1,0
W 1,0
W/SB
R/BL 1,5
BL
W 2,5
W 2,5
SB 1,5
GR/OR
BN/OR
OR
GR/W
W
GN/W
RY
47702487 11-2012 © AB VOLVO PENTA

9 33
R CYL. 1 4321
3
SB 1 θ2 1 2
4321
P4 MAIN RELAY HOLD 19 35
R CYL. 2
3
2
R 2,5
R 2,5
SB 1
OR 1,0
1 2
P 17
CYL. 3
26 1 2 2 1
R/BL 1,5
n n 1 2
1 2 R 25
3
32 18
13 14 CYL. 4
20
SB 4
R/W
R/Y
R4
BC AE D F 1 2 12345 SB 25
P0015340
16 B+ B- SB 25
G 31
30
n 4 R 25 3
2
39
1 - +
Description for wiring diagram TAD569(

BL = Blue
2 Main switch
LBL = Light blue
LBN = Light brown
4 Alternator
GN = Green
5 Main relay GR = Gray
OR = Orange
6 Aux stop
P = Pink
7 6-pole connector, engine interface R = Red
SB = Black
VO = Purple
9 Sensor, Boost air pressure / Air Temperature W = White
Y = Yellow
10 VODIA J1587 (diagnosis conn.)
11 Sensor, Ambient air temperature stated.
12
Visco electric fan
13 Sensor, Camshaft C = Clutch control low
14 Sensor, Flywheel (crank) B = Clutch control high
A = Fan speed sensor supply
15 E = Fan speed output
16 Unit injectors (4-cyl. engine) D = Fan speed sensor ground
F = Not connected
17 Preheater relay
18 Fuse preheater
19 Fuse 10A
20 Preheater
22
23 Sensor, Water in Fuel
24 Sensor, Oil pressure
25 Sensor, Fuel Pressure
26 Sensor, Rail pressure
27
28
29
30 Engine Control Unit, EMS 2.2 (MID 128)
31
32 MPROP
33 4-pole connector, preaheater relay
34 6-pole connector, EATS
35 Fuse 30A, EATS
36 2-pole connector, power supply EATS
37 Throttle
38 Sensor, Oil level / Oil temperature
39 Throttle
160 47702487 11-2012 © AB VOLVO PENTA

BATT.+
SWITCHED CAN BATT.+ 1708
CAN 1708 J1939 BATT.- SWITCHED J1587 BATT.+
J1939 J1587
HL AB
161
BATT.+ STOP BATT.-
HL AB 10
1 2 3 4 5 6 34 7 1 2 3 4 5 6 7 8 1 2 3 4 5 6 2 1 36
W/SB
Y/GR
BN/P
R/BL 1,5
SB 4
R/BL 1,5
CAN 2
R4
GN/SB
SB
SB 2,5
W
W/SB
R
GR/Y
R 2,5
Y/W
W
W/SB
Wiring Diagram TAD769(
R/BL 1 W
5
86
23 Y/SB
1
85
2 1 R/BL 1,5 R/BL 1,5 87
2
GR/OR
SB
30
4 6 R 1,5
Y
SB 2 4
3 1234567
1 R
3
SB
Y
38 5
37 24 21 CAN 3 SB 2,5
4M
R
4
SB 8 SB
2 SB 2
3
1 2P 1R 2 1
P5 SB 1
θ
2
SB SB
4 1 θ R/BL 1,0
R
1
2P 11
BN/OR 1,0
25
R/BL 1,5
R/BL 1,5
R/W 1,0
GN/SB
OR 1,0
BN 1,0
BL/OR
GN/BL
BL/GN
BL/GR
SB 1,0
SB 1,0
SB 1,5
SB 1,5
SB 1,5
GR/W
GN/W
BL/W
Y/GR
GR/Y
R 1,0
BN/P
LBN
Y/W
30
R/Y
GR
VO
BL
Y
1 5 24 11 16 17 18 31 27 3 4 49 23 10 8 52 56 22 21 29 25 37 57 60 7 58 59 61 51 55
h l h l h l
CONNECTOR B
R 2,5
CONNECTOR A BA
31 11 7 47 22 19 35 39 45 46 37 38 12 16 36 40 44 48 52 56 59 60 8 33 34 27 58 57
- +
GR/GN
GN
SB 1,0
R 1,0
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
Y/SB
W/SB
R/BL 1,5
BL
W 2,5
W 2,5
SB 1,5
GR/OR
BN/OR
OR
GR/W
W
GN/W
RY
47702487 11-2012 © AB VOLVO PENTA

9 33
R 3 CYL. 1 4321
SB 1 θ2 1 2
4321
P4 MAIN RELAY HOLD 19 35
R CYL. 2
3
2
R 2,5
R 2,5
SB 1
OR 1,0
1 2
P 17
CYL. 3
26 1 2 2 1
R/BL 1,5
n n 1 2
1 2 R 25
3
32 18
13 14 CYL. 4
20
SB 4
R/W
R/Y
R4
BC AE D F 1 2 12345 SB 25
CYL. 5 B+ B- SB 25
P0015341
G 31
M 30
n 1 2 4 R 25 3
CYL. 6
2
39 1 2
1 - +
16
Description for wiring diagram TAD761-765VE

BL = Blue
2 Main switch
LBL = Light blue
LBN = Light brown
4 Alternator
GN = Green
5 Main relay GR = Gray
OR = Orange
6 Aux stop
P = Pink
7 6-pole connector, engine interface R = Red
SB = Black
VO = Purple
9 Sensor, Boost air pressure / Air Temperature W = White
Y = Yellow
10 VODIA J1587 (diagnosis conn.)
11 Sensor, Ambient air temperature stated.
12
Visco electric fan
13 Sensor, Camshaft C = Clutch control low
14 Sensor, Flywheel (crank) B = Clutch control high
A = Fan speed sensor supply
15 E = Fan speed output
16 Unit injectors (6-cyl. engine) D = Fan speed sensor ground
F = Not connected
17 Preheater relay
18 Fuse preheater
19 Fuse 10A
20 Preheater
22
23 Sensor, Water in Fuel
24 Sensor, Oil pressure
25 Sensor, Fuel Pressure
26 Sensor, Rail pressure
27
28
29
30 Engine Control Unit, EMS 2.2 (MID 128)
31
32 MPROP
33 4-pole connector, preaheater relay
34 6-pole connector, EATS
35 Fuse 30A, EATS
36 2-pole connector, power supply EATS
37 Throttle
38 Sensor, Oil level / Oil temperature
39 Throttle
162 47702487 11-2012 © AB VOLVO PENTA

39-0 General
39-0 General
Index
MID 164: HCU
Caption SPN Flashcode / PID PPID SID PSID FMI
electrical
fault / value
fault
MID 128, PID 45 Inlet air heater sta-
626 5.4/- 45 3, 4, 5
tus page 45
MID 128, PID 94 Fuel Delivery Pres-
94 3.6/3.8 94 1, 3, 5, 7
sure page 47
MID 128, PID 97 Water in fuel indica-
97 2.9/2.1 97 0, 4
tor page 51
MID 128, PID 100 Engine oil pres-
100 3.1/6.6 100 1, 3, 5
sure page 53
MID 128, PID 105 Intake manifold tem-
105 3.2/6.2 105 0, 4, 5
perature page 56
MID 128, PID 106 Air inlet pres-
106 3.4/3.5 106 0, 3, 5
sure page 59
MID 128, PID 108 Barometric pres-
108 -/- 108 2, 3, 4
sure page 62
MID 128, PID 110 Engine coolant tem-
110 3.3/6.1 110 1, 3, 4
perature page 63
MID 128, PID 111 Coolant level page 66 111 2.3/2.2 111 1
MID 128, PID 158 ECU battery poten- -/3.9 (EMS)
158 158 1
tial page 68 -/6.9 (CIU)
MID 128, PID 164 Injection Control Pres-
164 8.3 164 0, 2, 4, 5
sure page 69
MID 128, PID 190 Engine speed 190 -/2.6 190 0
MID 128 / 144, PPID 4 Starter input sen-
4.7/5.2 4 3, 4
sor page 73
MID 128 / MID 144, PPID 6 Key off input 520195 4.8/- (EMS)
6 3, 4, 5
sensor page 74 970 5.3/- (CIU)
MID 128, PPID 19 Internal EGR Sta-
8.5/- 19 3, 4, 5, 7
tus page 76
MID 128, PPID 55 ECU temperature 8.4/- 55 0, 4, 5
MID 128, PPID 98 Engine sync acknowl-
608 - 98 9
edge
MID 128 / 144, PPID 132 Throttle cali-
608 2.8/- 132 3, 4, 9
brated position page 78
MID 128, SID 1/2/3/4/5/6 Injector # 651-65
7.1-7.6/- 1–6 3, 4, 5, 7, 12
1-6 page 80 6
47702487 11-2012 © AB VOLVO PENTA 163

39-0 General
Caption SPN Flashcode / PID PPID SID PSID FMI

electrical
fault / value
fault
MID 128, SID 21 Engine posi-
636 2.5/- 21 2, 3, 8
tion page 84
MID 128, SID 22 Timing sensor,
637 2.4/- 22 2, 3, 8
crank page 86
MID 128, SID 39 Engine Starter Motor 677/16
4.6 39 3, 4, 5
Relay page 88 75
MID 128, SID 42 Fuel control
679 8.3/- 42 3, 4, 5, 6, 13
unit page 91
MID 128, SID 70 Air inlet heater driver
729 70 3, 4, 5
#1 page 94
MID 128, SID 146 EGR Valve 1 page 96 2791 146 0, 2,4,7,12,13
MID 128, SID 211 Sensor Supply Voltage
9.3/- 211 3, 4
#2 (+5V DC) page 99
MID 128 / 144, SID 231 SAE J1939 data 6.5/- (EMS)
639 231 2
link page 100 6.4/- (CIU)
MID 128, SID 232 5 V supply page 102 620 9.3/- 232 3, 4
MID 128, SID 240 Program mem-
639 9.9/- 240 2, 7, 11, 14
ory page 103
MID 128 / MID 144, SID 250 SAE J1708/
608 9.2/- (EMS) 250 11
J1587 data link page 104
MID 128, SID 254 Controller 1 page 105 9.9/- (EMS)
629 254 3, 8, 12
9.8/- (CIU)
MID 128, PSID 96 Rail pressure sys-
1239 96 0, 1, 4, 7, 12
tem page 106
MID 128, PSID 97 Pressure Release
679 8.3 97 0, 7, 11, 14
Valve page 111
MID 128, PSID 201 Data link, 639/16
- 201 9
MID144 page 113 75
164 47702487 11-2012 © AB VOLVO PENTA

Alphabetical index
A D
About this Workshop manual..................................... 2 Design and Function................................................ 16
C E
Changing the engine control unit.............................. 33 Electrical System........................................................ 5
Checking air inlet pressure sensor......................... 125 Electrical Welding..................................................... 32
Checking camshaft sensor..................................... 133 EMS 2 (Engine Management System)..................... 16
Checking camshaft sensor wiring........................... 132 Engine Protection Map............................................... 7
Checking coolant level switch................................ 127 F
Checking coolant temperature sensor.................... 141 Fault Codes.............................................................. 45
Checking crankshaft sensor................................... 135 Fault Tracing............................................................ 43
Checking crankshaft sensor wiring......................... 134 Fault tracing of cables and connectors..................... 43
Checking fuel pressure sensor............................... 117
Checking IEGR coil................................................ 130 G
Checking IEGR solenoid........................................ 130 General................................................... 2, 16, 43, 163
Checking injection control pressure sensor............ 144 General advice......................................................... 42
Checking inlet manifold temperature sensor.......... 124 I
Checking negative cable, coolant level switch....... 126 Index....................................................................... 163
Checking negative cable, coolant temperature
L
sensor..................................................................... 138
Logging throttle signal with Vodia........................... 147
Checking negative cable, fuel sensor..................... 116
Checking negative cable, inlet manifold pres- M
sure/temperature sensor........................................ 122 Malfunctions............................................................. 40
Checking negative cable, oil pressure sensor........ 120 Manual fault tracing in bus cables............................ 39
Checking negative cable, rail pressure sensor....... 142 MID 128 / 144, PPID 132 Throttle calibrated position 78
Checking negative cable, water in fuel switch........ 118 MID 128 / 144, PPID 4 Starter input sensor............. 73
Checking oil pressure sensor................................. 121 MID 128 / 144, SID 231 SAE J1939 data link........ 100
Checking sensor cable, coolant temperature MID 128 / MID 144, PPID 6 Key off input sensor..... 74
sensor..................................................................... 140 MID 128 / MID 144, SID 250 SAE J1708/J1587
Checking sensor cable, inlet manifold temper- data link.................................................................. 104
ature sensor........................................................... 123 MID 128, PID 100 Engine oil pressure..................... 53
Checking signal cable, coolant temperature sensor 139 MID 128, PID 105 Intake manifold temperature....... 56
Checking signal cable, fuel sensor......................... 117 MID 128, PID 106 Air inlet pressure......................... 59
Checking signal cable, inlet manifold pressure MID 128, PID 108 Barometric pressure................... 62
sensor..................................................................... 125 MID 128, PID 110 Engine coolant temperature........ 63
Checking signal cable, inlet manifold tempera- MID 128, PID 111 Coolant level............................... 66
ture sensor............................................................. 121 MID 128, PID 158 ECU battery potential.................. 68
Checking signal cable, oil pressure sensor............ 120 MID 128, PID 164 Injection Control Pressure ......... 69
Checking signal cable, rail pressure sensor........... 143 MID 128, PID 45 Inlet air heater status.................... 45
Checking starter motor relay coil............................ 128 MID 128, PID 94 Fuel Delivery Pressure................. 47
Checking starter motor relay voltage supply.......... 128 MID 128, PID 97 Water in fuel indicator................... 51
Checking supply cable, coolant level switch.......... 126 MID 128, PPID 19 Internal EGR Status................... 76
Checking supply cable, fuel sensor........................ 115 MID 128, PSID 201 Data link, MID144................... 113
Checking supply cable, inlet manifold pressure MID 128, PSID 96 Rail pressure system................ 106
sensor..................................................................... 124 MID 128, PSID 97 Pressure Release Valve........... 111
Checking supply cable, oil pressure sensor........... 119 MID 128, SID 1/2/3/4/5/6 Injector # 1-6.................... 80
Checking supply cable, rail pressure sensor.......... 142 MID 128, SID 146 EGR Valve 1............................... 96
Checking supply cable, water in fuel switch........... 118 MID 128, SID 21 Engine position............................. 84
Checking the CAN bus cable......................... 136, 137 MID 128, SID 211 Sensor Supply Voltage #2
Checking the charging system................................. 37 (+5V DC).................................................................. 99
Checking the injectors............................................ 131 MID 128, SID 22 Timing sensor, crank.................... 86
Checking the preheat relay.................................... 115 MID 128, SID 232 5 V supply................................. 102
Checking the solenoid in the MPROP valve........... 146 MID 128, SID 240 Program memory...................... 103
Checking the starter motor voltage.......................... 36 MID 128, SID 254 Controller 1............................... 105
Checking the wiring................................................ 129 MID 128, SID 39 Engine Starter Motor Relay ......... 88
Checking the wiring to the MPROP valve.............. 145 MID 128, SID 42 Fuel control unit............................ 91
Checking water in fuel switch................................. 119 MID 128, SID 70 Air inlet heater driver #1................ 94
Component description............................................ 26 O
Component location................................................. 19 Other Special Equipment......................................... 15
Concerned engines.................................................... 2
47702487 11-2012 © AB VOLVO PENTA 165

P
Programming an empty control unit......................... 35
R
Rail pressure measurement..................................... 38
Repair Instructions................................................... 32
Repair instructions...................................................... 3
Reprogramming a control unit.................................. 34
S
Safety Instructions.................................................... 10
Special Service Tools............................................... 14
Specifications, Electrical............................................. 5
T
Technical Data........................................................... 5
V
VODIA Log Parameters.......................................... 147
W
Wiring Diagrams..................................................... 148
166 47702487 11-2012 © AB VOLVO PENTA

References to Service Bulletins
Group No. Date Refers to
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167
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Do you have any comments or other views about this manual? If so,
make a copy of this page, write down your views and send them to us.
The address is at the bottom. We would prefer you to write in Swedish
or English.
From:.........................................................................
..................................................................................
..................................................................................
..................................................................................
Refers to publication:...................................................................................................................................
Publication No.:....................................Date of issue:..................................................................................
Proposal/motivation:....................................................................................................................................
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Date:.....................................................................................
Signed:.................................................................................
AB Volvo Penta
Service Communication
Dept. 42200
SE-405 08 Göteborg
Sweden
47702487 English 11–2012

Workshop Manual: Group 30 Electrical System I

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Workshop Manual: Group 30 Electrical System I

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Workshop Manual I

Group 30 Electrical system 5(0)

TAD734GE, TAD550-551GE, TAD750-751GE,

Safety and Other Instructions

General, Complete Vehicle Software

Cables and fuses

47702487 11-2012 © AB VOLVO PENTA 1

• TAD550GE • TAD752GE • TAD560VE • TAD750VE • TAD763VE

About this Workshop manual

Volvo Penta accepts no responsibility for damage or

2 47702487 11-2012 © AB VOLVO PENTA

Above all, when working on fuel systems, hydraulic

47702487 11-2012 © AB VOLVO PENTA 3

Lock nuts Anaerobic agents.

4 47702487 11-2012 © AB VOLVO PENTA

03-3 Specifications, Electrical

Sensor, Fuel Pressure

Speed sensor, Camshaft / Speed sensor, Crankshaft

Sensor, Oil pressure

Sensor, Rail pressure

Combination sensor, Air inlet pressure / Inlet manifold temperature

47702487 11-2012 © AB VOLVO PENTA 5

Working pressure range 50–400 kPa (0.5-4 bar) (7.3–58.0 PSI)

Sensor, Coolant temperature

Switch, Coolant Level

6 47702487 11-2012 © AB VOLVO PENTA

Engine Protection Map

Derate to engine protection map

Oil pressure limit A Engine protection

47702487 11-2012 © AB VOLVO PENTA 7

Parameter “Yellow lamp” “Red lamp” Forced shutdown

Oil pressure limit

TAD550-551GE, 750-751GE, 752-754GE

Parameter Unit Warning level Alarm level Engine protection

TAD752-754GE: TAD752-754GE: TAD752-754GE:

TAD752-754GE: TAD752-754GE: TAD752-754GE:

8 47702487 11-2012 © AB VOLVO PENTA

Parameter Warning level Alarm level Engine protection

Parameter Engine protection

1. OFF: Disables the function, i.e. no shut down.

47702487 11-2012 © AB VOLVO PENTA 9

05-1 Safety Instructions

10 47702487 11-2012 © AB VOLVO PENTA

47702487 11-2012 © AB VOLVO PENTA 11

Do not touch the connections during start

12 47702487 11-2012 © AB VOLVO PENTA

Fuel delivery pipes must not be bent or straight-

47702487 11-2012 © AB VOLVO PENTA 13

08-2 Special Service Tools

885675 Break-out cable 9990014 Break-out cable 9990136 Break-out cable

9998482 Measuring tool 9998699 Break-out box 88890016 Break-out cable

88820047 VODIA, diagnostic 88890058 Pliers 88890074 Multimeter

14 47702487 11-2012 © AB VOLVO PENTA

Other Special Equipment

47702487 11-2012 © AB VOLVO PENTA 15

Design and Function

The system consists of a control unit, six unit injectors,

CAN - Controller Area Network

If a fault develops on the CAN link, signals for the

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

CIU - Control Interface Unit

The fast one is a CAN link that features a bus speed

The slower J1708/J1587 link handles diagnostic infor-