Professional Documents
Culture Documents
General Information
00-0 General ................................................................................................ 2
Specifications
03-3 Specifications, Electrical ................................................................... 5
Electrical System ........................................................................................ 5
Engine Protection Map ............................................................................... 7
Special tools
08-2 Special Service Tools ....................................................................... 14
Miscellaneous
39-0 General ............................................................................................ 163
Alphabetical index .................................................................................. 165
References to Service Bulletins ............................................................ 167
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.
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.
Electrical System
Technical Data
Switch, Water in Fuel
Voltage 24 V
Connector 2–pin
Contact type Closes when water is detected
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
Y 1500
1000
500
A
0
0 500 1000 1500 2000 2500 3000 3500 X
P0015455
TAD734GE
TAD560-56VE, TAD761-765VE
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.
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.
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.
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.
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.
8856
75 p0013275
P0008793
5
4
3
2
1
P0006701
p0005128
VODIA
p0005125
p0008375
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.
30-0 General
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.
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.
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
10
11
P0015430
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
11
8
P0015433 P0015432
TAD550/551GE
10
2
8 9
11
4
P0015181
7
TAD750/751GE
10
2
8 9
11
P0015182
7
TAD752/753/754GE
2
11 3
9 10
6
12
P0015185
7
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
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
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
Injectors
The injectors are installed on the cylinder head.
P0015435
TAD734GE, TAD752/753/754GE,
P0008694 TAD560-561VE, TAD761-765VE
TAD734GE, TAD752/753/754GE,
TAD560-561VE, TAD761-765VE
P0015437
P0015439
P0015441
P0015443
P0015442
0016493
TAD752-754GE, TAD560-561VE,
TAD550-751GE TAD761-765VE
TAD734GE
P0015444
P0015445
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.
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.
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
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”.
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.
General
If battery voltage falls below 24.7 V*, the starter motor
will not be able to crank the engine at normal speed.
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.
2
1
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
IMPORTANT!
Cut the current with the main switch before the cables
are disconnected.
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.
General advice
NOTICE! The following must be done before fault trac-
ing continues, to avoid changing functional sensors:
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.
J1587
The communication bus, J1587, is also used for acces-
sories and for diagnostics.
General
Fault tracing of cables and
connectors
Tools:
88890074 Multimeter
9998482 Measuring tool
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.
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.
Open circuit
Possible reasons for faults could be chafed or broken
cables, or connectors which have come undone.
Fault Codes
MID 128, PID 45 Inlet air heater
status
MID 128: Engine control unit
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.
Flash code
Electrical fault: 5.4
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.
Flash code
Electrical fault: 5.4
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.
Flash code
Electrical fault: 3.6
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
Flash code
Electrical fault: 3.6
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
Flash code
Electrical fault: 3.6
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
Flash code
Electrical fault: 3.6
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
B Circuit description
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
Flash code
Electrical fault: 2.9
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
Flash code
Electrical fault: 2.9
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
Flash code
Electrical fault: 2.9
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
Flash code
Electrical fault: 3.1
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
Flash code
Electrical fault: 3.1
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
Flash code
Electrical fault: 3.1
Value fault: 6.6
Symptom: None
Conditions for fault code: The voltage on pin B11 on the EMS 2 is less than 0.07 Volt.
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
TAD650/660/750/760VE
B Circuit description
The sensor is an active sensor, i.e. the sensor must
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
Component specification
Working range: 0 – 7 bar = 0 – 700 kPa
Supply voltage: 5,00 +/- 0,25 VDC
Flash code
Electrical fault: 3.2
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
Flash code
Electrical fault: 3.2
Value fault: 6.2
Symptom: Temperature is set to 40° C.
Conditions for fault code: The voltage on pin B47 on the EMS 2 is less than 0.07 Volt.
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.
2 Check function of inlet manifold temperature sensor.
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
Flash code
Electrical fault: 3.2
Value fault: 6.2
Symptom: Temperature is set to 40° C.
Conditions for fault code: The voltage on pin B47 on the EMS 2 is more than 4.95 Volt.
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.
3 Check function of inlet manifold temperature sensor.
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
A Circuit description
(+) 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.
Flash code
Electrical fault: 3.4
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
Flash code
Electrical fault: 3.4
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
• Checking negative cable, inlet manifold pressure/temperature
sensor page 122
• Checking signal cable, inlet manifold pressure sensor page 125
• Checking air inlet pressure sensor page 125
Flash code
Electrical fault: 3.4
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.
Suitable action: 1 Check contact pressure in socket 22 and 11 in engine connector A. Also
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
• Checking negative cable, inlet manifold pressure/temperature
sensor page 122
• Checking signal cable, inlet manifold pressure sensor page 125
• Checking air inlet pressure sensor page 125
A Circuit description
(+) 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.
Component specification
Working range: 0,5 – 4,0 bar = 50 – 400 kPa
Supply voltage: 5,00 +/- 0,25 VDC
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).
Flash code
Electrical fault: None
Value fault: None
Symptom: Ambient pressure is set to 1.0 bar.
Conditions for fault code: Internal fault in the engine control unit.
Suitable action: 1 Replace the engine control unit (EMS 2).
Flash code
Electrical fault: None
Value fault: None
Symptom: Ambient pressure is set to 1.0 bar.
Conditions for fault code: Internal fault in the engine control unit.
Suitable action: 1 Replace the engine control unit (EMS 2).
Component description
Sensor is placed inside the engine control unit and is
not replaceable.
Flash code
Electrical fault: 3.3
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
Flash code
Electrical fault: 3.3
Value fault: 6.1
Symptom: Engine is difficult to start
Conditions for fault code: The voltage on pin B18 on the EMS 2 is less than 0.07 Volt.
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.
2 Check function of coolant temperature sensor.
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
Flash code
Electrical fault: 3.3
Value fault: 6.1
Symptom: Engine is difficult to start
Conditions for fault code: The voltage on pin B27 on the EMS 2 is more than 4.95 Volt.
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.
3 Check function of coolant temperature sensor.
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
B Circuit description
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.
Flash code
Electrical fault: 2.3
Value fault: 2.2
Symptom: VE engines: Engine is derated if engine protection parameter is activated.
Flash code
Electrical fault: 2.3
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
B Circuit description
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.
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.
Lamp status
FMI 0: None
FMI 2,4,5: Yellow lamp
Flash code
Electrical fault: 8.3
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
Lamp status
FMI 0: None
FMI 2,4,5: Yellow lamp
Flash code
Electrical fault: 8.3
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
Lamp status
FMI 0: None
FMI 2,4,5: Yellow lamp
Flash code
Electrical fault: 8.3
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: 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.
• Faulty rail pressure sensor.
Suitable action: 1 Check cable harness and connectors between rail pressure sensor and
EMS 2.
2 Check function of rail pressure sensor.
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
Lamp status
FMI 0: None
FMI 2,4,5: Yellow lamp
Flash code
Electrical fault: 8.3
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: 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.
• Faulty rail pressure sensor.
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.
3 Check function of rail pressure sensor.
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
A Circuit description
splice
The sensor is an active sensor, i.e. the sensor must
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!
Only TAD650/660/750/760VE has a 42-pin connector.
Component specification
Working range: 0 – 1800 bar = 0 – 180 MPa
Supply voltage: 5.00 +/- 0.25 VDC
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.
Flash code
Electrical fault: 4.7 (EMS)
Value fault: None (EMS)
Electrical fault: 5.2 (CIU)
Value fault: None (CIU)
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.
Flash code
Electrical fault: 4.8 (EMS)
Value fault: None (EMS)
Electrical fault: 5.3 (CIU)
Value fault: None (CIU)
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.
Flash code
Electrical fault: 4.8 (EMS)
Value fault: None (EMS)
Electrical fault: 5.3 (CIU)
Value fault: None (CIU)
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.
2 Check function of aux stop button at EMS / stop button at CIU.
Flash code
Electrical fault: 4.8 (EMS)
Value fault: None (EMS)
Electrical fault: 5.3 (CIU)
Value fault: None (CIU)
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.
2 Check function of aux stop button at EMS / stop button at CIU.
Flash code
Electrical fault: 8.5
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
Fault code explanation: Faulty sensor / Faulty sensor circuit
Fault indication: DCU: Engine warning in DCU display.
CIU: None
Flash code
Electrical fault: 8.5
Value fault: None
Symptom: IEGR can not be turned on.
Possible reason: • Short circuited IEGR signal cable to battery negative.
Suitable action: 1 Check cable harness and connectors between EMS 2 and IEGR.
Measurements: • Checking the wiring page 129
Flash code
Electrical fault: 8.5
Value fault: None
Symptom: IEGR can not be turned on.
Possible reason: • An open circuit in one or both of the cables to the IEGR.
Suitable action: 1 Check cable harness and connectors between EMS 2 and IEGR.
2 Check IEGR coil.
Measurements: • Checking the wiring page 129
• Checking IEGR coil page 130
Flash code
Electrical fault: 8.5
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
Flash code
Electrical fault: 2.8
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
Fault indication: DCU: Engine warning in DCU display
CIU: Flash code
Flash code
Electrical fault: 2.8
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: • Short circuited throttle potentiometer signal cable to battery negative.
• 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.
Flash code
Electrical fault: 2.8
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.
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.
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.
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
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 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).
Measurements • Checking the injectors page 131
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 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).
Measurements • Checking the injectors page 131
Flash code
Electrical fault: 7.1–7.6
Value fault: None
Symptom: None
Preconditions: NOTICE! Identify which injector by the SID number.
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.
Measurements • Checking the injectors page 131
Flash code
Electrical fault: 7.1– 7.6
Value fault: None
Symptom: None
Preconditions: NOTICE! Identify which injector by the SID number.
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.
Measurements • Checking the injectors page 131
Flash code
Electrical fault: 7.1– 7.6
Value fault: None
Symptom: None
Preconditions: NOTICE! Identify which injector by the SID number.
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.
Measurements • Checking the injectors page 131
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!
Only TAD650/660/750/760VE has a 42-pin connector.
Flash code
Electrical fault: 2.5
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
Flash code
Electrical fault: 2.5
Value fault: None
Symptom: The engine start time will increase, uses only crankshaft sensor.
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.
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
Flash code
Electrical fault: 2.5
Value fault: None
Symptom: The engine start time will increase, uses only crankshaft sensor.
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.
2 Check contact pressure in socket 45 and 46 in engine connector A.
3 Check installation of cam sensor.
4 Attempt to localize the source of interference.
5 Check function of cam sensor.
Measurements • Checking camshaft sensor wiring page 132
• Checking camshaft sensor page 133
A Circuit description
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!
Only TAD650/660/750/760VE has a 42-pin connector.
Flash code
Electrical fault: 2.4
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
Flash code
Electrical fault: 2.4
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.
2 Check contact pressure in socket 37 and 38 in engine connector A.
3 Check installation of crankshaft sensor.
4 Check function and clean the crankshaft sensor.
Measurements • Checking crankshaft sensor wiring page 134
• Checking crankshaft sensor page 135
Flash code
Electrical fault: 2.4
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.
2 Check contact pressure in socket 37 and 38 in engine connector A.
3 Check installation of crankshaft sensor.
4 Attempt to localize the source of interference.
5 Check function and clean the crankshaft sensor.
Measurements • Checking crankshaft sensor wiring page 134
• Checking crankshaft sensor page 135
A Circuit description
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!
Only TAD650/660/750/760VE has a 42-pin connector.
Flash code
Electrical fault: 4.6
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
Flash code
Electrical fault: 4.6
Value fault: Flash code
Symptom: Start motor does not engage.
Conditions for fault code: Short circuit too battery negative.
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
Flash code
Electrical fault: 4.6
Value fault: Flash code
Symptom: Start motor does not engage.
Conditions for fault code: Open Circuit
Possible reason: • An open circuit in starter relay cable.
• Faulty starter relay.
Suitable action: 1 Check cable harness and connections between starter relay and EMS
2.
2 Check contact pressure in socket B29 in engine connector.
3 Check function of starter relay.
Measurements: • Checking starter motor relay coil page 128
• Checking starter motor relay voltage supply page 128
B Circuit description
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!
Only TAD650/660/750/760VE has a 42-pin connector.
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
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 negative in MPROP positive wire, pin 1 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
Flash code
Electrical fault: 8.3
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.
Suitable action: 1 Check contact pressure in socket 12 and 16 in engine connector A. Also
check contact pressure in connector at MPROP.
2 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
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 negative in MPROP negative cable, pin 2 on
MPROP.
• An open circuit in one or both cables from EMS 2 to MPROP.
Suitable action: 1 Check contact pressure in socket 12 and 16 in engine connector A. Also
check contact pressure in connector at MPROP.
2 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
Flash code
Electrical fault: 8.3
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.
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
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
Flash code
Electrical fault: None
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.
Flash code
Electrical fault: None
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
at the heating element.
Flash code
Electrical fault: None
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
at the heating element.
3 Check heating element.
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.
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.
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.
Flash code
Electrical fault: 9.3
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)
Flash code
Electrical fault: 9.3
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.
Flash code
Electrical fault: 6.5 (EMS)
Value fault: None (EMS)
Flash code
Electrical fault: 9.3
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)
Flash code
Electrical fault: 9.3
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.
Flash code
Electrical fault: 9.9
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.
Flash code
Electrical fault: None
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.
Flash code
Electrical fault: 9.9 (EMS)
Value fault: None (EMS)
Electrical fault: 9.8 (CIU)
Value fault: None (CIU)
Symptom: The engine can not be started.
Conditions for fault code: Internal fault in the engine control unit.
Suitable action: 1 Replace the engine control unit.
Lamp status
FMI 0,12: Yellow lamp
FMI 1, 4, 7: Red lamp
Flash code
Electrical fault: 8.3
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.
• Faulty rail pressure sensor.
• 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)
3 Check function of rail pressure sensor.
4 Change MPROP valve.
5 Check if an injector is faulty.
Lamp status
FMI 0,12: Yellow lamp
FMI 1, 4, 7: Red lamp
Flash code
Electrical fault: 8.3
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.
• Faulty rail pressure sensor.
• 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.
4 Check MPROP cables and connectors. (see "Checking the solenoid in
the MPROP valve" under MID128, SID 42)
5 Change MPROP valve.
6 Check if an injector is faulty.
7 Check both high pressure pumps (see workshop manual Group 21-26).
Lamp status
FMI 0,12: Yellow lamp
FMI 1, 4, 7: Red lamp
Flash code
Electrical fault: 8.3
Value fault: None
Symptom: Engine derated: engine speed limitation (1100 rpm). Fuel pressure limitation
(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.
• Faulty rail pressure sensor.
• 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 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).
5 Change the rail pressure release valve.
6 Check MPROP cables and connectors. (see "Checking the solenoid in
the MPROP valve" under MID128, SID 42)
7 Change MPROP valve.
8 Check if an injector is faulty.
9 Check both high pressure pumps (see workshop manual Group 21-26).
Lamp status
FMI 0,12: Yellow lamp
FMI 1, 4, 7: Red lamp
Flash code
Electrical fault: 8.3
Value fault: None
Symptom: Engine derated: engine speed limitation (1100 rpm). Fuel pressure limitation
(800 bar). Engine torque reduction.
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.
Lamp status
FMI 0,12: Yellow lamp
FMI 1, 4, 7: Red lamp
Flash code
Electrical fault: 8.3
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 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.
• Faulty rail pressure sensor.
• 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 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)
5 Change the rail pressure release valve.
6 Check MPROP cables and connectors. (see "Checking the solenoid in
the MPROP valve" under MID128, SID 42)
7 Change MPROP valve.
8 Check if an injector is faulty.
9 Check both high pressure pumps.
Lamp status
FMI 0, 11, 14: Yellow lamp
FMI 7: Red lamp
Flash code
Electrical fault: 8.3
Value fault: None
Symptom: Engine derated: engine speed limitation (1100 rpm). Fuel pressure limitation
(800 bar). Engine torque reduction.
Conditions for fault code: Leakage detected in pressure release valve, open mode.
Possible reason: • Rail pressure controller out of range.
• Faulty pressure release valve.
Suitable action: 1 Check function of rail pressure sensor.
2 Change the pressure release valve.
Lamp status
FMI 0, 11, 14: Yellow lamp
FMI 7: Red lamp
Flash code
Electrical fault: 8.3
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.
Suitable action: 1 Check contact pressure in socket 12 and 16 in engine connector A. Also
check contact pressure in connector at MPROP.
2 Check cable harness and connectors between EMS 2 and MPROP.
3 Change the pressure release valve.
Lamp status
FMI 0, 11, 14: Yellow lamp
FMI 7: Red lamp
Flash code
Electrical fault: 8.3
Value fault: None
Symptom: Engine derated: engine speed limitation (1100 rpm). Fuel pressure limitation
(800 bar). Engine torque reduction.
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.
Suitable action: 1 Check function of rail pressure sensor.
2 Change the pressure release valve.
Lamp status
FMI 0, 11, 14: Yellow lamp
FMI 7: Red lamp
Flash code
Electrical fault: 8.3
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
check contact pressure in connector at MPROP.
3 Check cable harness and connector between EMS 2 and MPROP.
4 Change MPROP valve.
5 Change the rail pressure release valve.
Flash code
Electrical fault: None
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
Measurements
Checking the preheat relay
Tools:
9990014 Break-out cable
9998699 Break-out box
88890074 Multimeter
p0013473
75
8856 885675
5
4
3
2
4
1
P0010786
75
8856
5
4
3
2
4
1
2
p0010784
P0010785
2
1
3
1
P0010787
75
8856
885675
5
4
3
2
1
3
P0010788
75
8856
885675
5
4
3
2
1
3
2
P0015362
75
8856
5
4
3
2
1
3
2
P0015363
2
1
P0015365 2
1
75
8856
885675
5
4
3
2
1
P0015364 1
2
1 (885675) – 11 (EMS 2, conn.A) R ≈ 0 Ω
1
1 885675
NOTICE! Measurement is done to eliminate short cir-
cuiting or breaks in the cable to the engine control unit.
75
8856
5
4
3
2
1
2
P0015366
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
2
1
3
1
P0013487
75
NOTICE! Measurement is done to eliminate short cir-
8856
885675 cuiting or breaks in the cable to the engine control unit.
5
4
3
2
4
1
P0013488 1
4
P0013489
1
P0015371
75
8856 885675
5
4
3
2
1
2
P0015373 1
P0015382
P0015383
P0015376
LTS
VO
P0015377
P0015378
IMPORTANT!
4
3
2
1
75
8856
5
4
3
2
1
P0015379
2
1
P0015380
IMPORTANT!
4
3
2
1
75
8856
5
4
3
2
1
P0015379
2
1
P0015380
Tools:
9990014 Break-out cable
9998699 Break-out box
88890074 Multimeter
or
Tools:
88890074 Multimeter
88890016 Break-out cable
9998699 Break-out box
or
75
8856
885675
5
4
3
2
1
P0015368 1
75
8856
885675
5
4
3
2
1
P0015367 2
1
2
1 (885675) – 18 (EMS 2, conn.B) R ≈ 0 Ω
1
2 885675
NOTICE! Measurement is done to eliminate short cir-
cuiting or breaks in the cable to the engine control unit.
75
8856
5
4
3
2
1
1
P0015369
1–2 R ≈ 596 Ω
3
2
1
75
8856
5
4
3
2
1
3
1
P0010787
75
8856 885675
5
4
3
2
1
P0015374 1
75
8856
885675
5
4
3
2
1
2
P0015375
1
75
8856
5
4
3
2
1
2
1
P0013317
2
1
2 885675
75
8856
5
4
3
2
1
P0015384
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
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
37-0 Wiring Diagrams
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
37-0 Wiring Diagrams
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
37-0 Wiring Diagrams
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
37-0 Wiring Diagrams
Description TAD734GE
P0015454
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
Description CIU
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
9 8-pin connector engine interface
Y = Yellow
10 Termination resistance 120 Ohm
Cable cross section = 0.75 mm2 unless otherwise
11 Display Control unit (DCU)
stated.
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
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 - +
37-0 Wiring Diagrams
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
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
37-0 Wiring Diagrams
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
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Date:.....................................................................................
Signed:.................................................................................
AB Volvo Penta
Service Communication
Dept. 42200
SE-405 08 Göteborg
Sweden
47702487 English 11–2012