Volvo TAD650VE Workshop Manual Download Page 27

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Group 30: Electrical system

Repair instructions

Joining electrical cables for
connectors

Special tools: 9808648, 999 9324

Repair kit: 107 8054

Disconnect the connector from the engine control unit
or from the power supply unit, please refer to ”Control
unit, changing”.

Undo the connector, to gain access to the cable lead-
ing to the pin which is to be changed.

Undo the pin catch.

Remove the pin with tool no. 9808648.

NOTE!

Only remove one pin at a time.

Cut off the cable and the pin which is to be changed.
Join the cable with the new one, using repair kit
10.78054. Use cable crimping tool no. 999 9324.

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

Summary of Contents for TAD650VE

Page 1: ...Workshop Manual Group 30 TAD650VE TAD660VE TAD734GE TAD750VE TAD760VE I 4 0 ...

Page 2: ......

Page 3: ... engine 15 EGR 15 Coolanttemperaturesensor 16 Sensor common rail pressure fuel 16 Sensor fuel pressure 16 Magneticallycontrolledproportionalvalve MPROP 17 Water in fuel switch secondary fuel filter 17 Switch coolant level 17 Preheater 18 Engine control unit EMS 2 18 Repairinstructions 19 General advice on working with EMS engines 19 Electric welding 20 Changing the engine control unit 21 Reprogram...

Page 4: ...tioncontrolpressureregulator 118 MID 128 SID 70 Preheatsense 122 MID 128 SID 211 5V sensor supply 2 124 MID 128 SID 231 Communication fault J 1939 126 MID 128 SID 232 5V sensor supply 1 129 MID 128 SID 240 Programmemory 131 MID 128 SID 254 Controllererror 132 MID 128 PSID 96 Rail pressure system 133 MID 128 PSID 97 Rail pressure release valve 137 MID 128 MID 144 PSID 201 J1939 communication bus 14...

Page 5: ...rongly connected this can cause severe damage to the electrical equipment Please refer to the wiring diagram Always use goggles when charging and han dling batteries Battery electrolyte contains sul furic acid which is highly corrosive If battery acid comes into contact with your skin wash it off at once with a lot of soap and water and then get medical help If battery acid comes into contact with...

Page 6: ... and fuel systems are subject to various national safety requirements Volvo Penta Original Spare Parts meet these specifications Any kind of damage whatsoever occasioned by use of non original Volvo Penta spares for the product in question will not be compensated by the warranty of fered by Volvo Penta Certified engines When doing service and repair on emission certi fied engines it is important t...

Page 7: ... tools are used when carrying out the repair Volvo Penta Special Tools have been de veloped to ensure the most safe and rational working methods possible It is therefore the responsibility of anyone using other tools or other working methods than we recommend to determine that there is no risk of personal injury or mechanical damage or malfunc tion as a result In some cases special safety precauti...

Page 8: ...the environment Volvo Penta recom mends the use of biodegradable degreasers whenever engine components are de greased unless otherwise specified in the workshop manual When working aboard a boat be careful to ensure that oils wash residue etc are processed for destruction and are not inadvertently discharged with bilge water into the envi ronment Tightening torques The tightening torque for vital ...

Page 9: ...21 on the engine s communi cation connector Note More detailed information about using the VODIA tool can be found in the tool s instruction manual 885675 Adapter cable for sensor test 9812519 Multimeter 9999324 Terminal crimping tool 9998482 Gauge for connector on control unit 9998699 Measurebox 88890016 Adapter cable 885675 3838619 3838620 3838621 3838622 9812519 Special tools Group 30 Electrica...

Page 10: ...er Area Network The J1939 CAN link is responsible after all communi cation between the engine control unit EMS 2 and a communication interface such as CIU DCU except for diagnostics Diagnostics are managed by the so called J1708 J1587 link The CAN link is much faster than the J1708 J1587 link and has been designed to connect to other components that support the SAE J1939 protocol such as instrumen...

Page 11: ...faults Parameter setting Idling speed alarm limit for oil temperature cool ant temperature droop Preheating for ignition Information Information about hardware software and engine identification CIU Control Interface Unit The CIU is a translator between the CAN bus and the customer s own control panel This unit has two serial communication links one fast and one slow The fast one is a CAN link tha...

Page 12: ...the fuel valve is open fuel is sprayed into the cylinder The parameters which govern the amount of fuel in jected are Demanded engine speed Engine protector functions Temperature Boost pressure Altitude correction The control unit contains an atmospheric pressure sensor and an altitude compensation function for en gines that operate at high altitude This function limits the fuel volume in relation...

Page 13: ...ection EMS 2 3 Solenoid controlled proportional valve high pres sure pump fuel MPROP 4 Fuel pressure 5 Fuel pressure in comman rail 6 Glow plugs one for each injector 7 Oil pressure sensor 8 Boost pressure and temperature 9 Solenoid valve EGR 10 Coolant temperature 11 Speed sensor crankshaft 12 Water in fuel not shown mounted on primary fuel filter 1 2 3 4 5 6 7 8 9 10 11 ...

Page 14: ...e high pressure pump fuel MPROP 2 Coolant temperature sensor 3 Water in fuel switch mounted on primary fuel filter 4 Boost pressure and temperature sensor 5 Preheater intake manifold 6 Fuel pressure in comman rail 7 Fuel pressure sensor 8 Oil pressure sensor 9 Main relay 10 Speed sensor crankshaft 11 Speed sensor camshaft ...

Page 15: ...nstalled in the flywheel housing on the left hand side of the engine The starter motor relay is positive connected which means that the re lay is connected to battery voltage Alternator The alternator is belt driven and mounted on the front of the engine on the right Component description ...

Page 16: ...d the torsion damper The impulses create a pulse signal in the sensor that the engine control unit EMS 2 uses to calculate the crankshaft s rpm The tooth wheel has a tooth free gap for the EMS 2 to recognize the crankshafts position The signal is sent to the engine control unit which calculates the injection in advance and the amount of fuel to be injected Speed sensor camshaft cam shaft position ...

Page 17: ... is pro portional to absolute pressure The boost temperature sensor consists of a non lin ear resistor whose resistance varies with boost tem perature The resistance falls as the temperature ris es Sensor oil pressure engine Oil pressure is measured by a sensor installed in the engine block on the right side of the engine The sensor measures pressure in the main oil gallery and is supplied by a 5 ...

Page 18: ...ed on the cylinder head at the rear end of the engine The sensor senses the engine coolant temperature and sends the information to the engine control unit The sensor consists of a non linear resistor whose re sistance varies with coolant temperature The resis tance falls as the coolant temperature rises Sensor common rail pressure fuel The sensor is mounted on the right of the engine at the front...

Page 19: ... is changed this af fects the fuel flow which results in changed rail pres sure Water in fuel switch secondary fuel filter A switch is located in the water trap under the fuel fil ter Its task is to detect whether there is water in the fuel The switch senses the resistance between two pins wich are in contact with the fuel When there is no wa ter in the fuel the resistance is very high If there is...

Page 20: ...r and the combined sensor for boost pressure boost temperature The EMS 2 system processor is located in the control unit protected from water and vibration The processor receives continuous information about Engine speed Throttle Oil pressure Boost pressure temperature Fuel pressure common rail pressure Fuel alarm water in fuel Camshaft position Coolant temperature The information provides informa...

Page 21: ...ed Never disconnect the current with the main switches when an engine is running Never undo a battery cable when the engine is running Turn the main switches off or disconnect the bat tery cables during quick charging of the batteries NOTE 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 ver...

Page 22: ...rts Turn the locking arm down at the same time as the con nector is pulled outwards 3 Disconnect all connections to the alternator Connect the welder earth clamp to the component to be welded or as close as possible to the weld site The clamp must never be connected to the engine or in such a way that current can pass through a bearing IMPORTANT After welding is completed the disconnected componen...

Page 23: ...ystem voltage when the engine control module connectors are disconnected or con nected 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 ...

Page 24: ...on in VODIA to check that the software has been downloaded 6 Connect the VODIA to the engine control unit to be programmed 7 Start with the engine control unit Select Engine with mounting and equipment in the VODIA menu Select MID 128 Control unit programming VODIA will guide you through the entire program ming process 8 The next control unit is the vehicle ECU Select Electrical system and instrum...

Page 25: ... refer to Programming a control unit If the part numbers do not coincide proceed as possible 1 Have both part numbers available 2 Log in to Volvo Penta Network s web site www vppn com 3 Choose VODIA in the left hand menu 4 Choose Conversion kit in the left hand menu A new page Conversion kit Accessory kit opens up 5 Click the text Available conversions kits which is shown in bold face 6 A new wind...

Page 26: ...ttent contact or temporary recurring faults can be difficult to fault trace and are frequently caused by oxidation vibration or poorly terminated cables Wear can also cause faults For this reason avoid dis connecting a connector unless it is necessary Other contact problems can be caused by damage to pins sockets and connectors etc Shake cables and pull connectors during measure ment to find where...

Page 27: ...ontrol unit changing Undo the connector to gain access to the cable lead ing to the pin which is to be changed 2 Undo the pin catch 3 Remove the pin with tool no 9808648 NOTE Only remove one pin at a time 4 Cut off the cable and the pin which is to be changed Join the cable with the new one using repair kit 10 78054 Use cable crimping tool no 9999324 5 Carefully heat the joint with a hot air gun t...

Page 28: ... voltage between terminal B on the start er motor and battery negatives connection point is the same as the battery voltage 6 Put the pin back in the right place in the connector be fore removing the next pin if several pins are to be changed Check that the locking tongue locks the pin in the connector 7 Install the cables with insulation and tie wraps in the connector in the reverse order to disa...

Page 29: ...prox 25 4V 3 Engine on Run at 1500 rpm 4 Use multimeter 9812519 to do a voltage measure ment over the battery The nominal charging volt age over the battery should be approx 27 8 28 6V Fault tracing charging system Battery 1 Check that all connectors at the battery is correct assembled 2 Check the conditions of the cables to the battery 3 Check the water level in the battery 4 Check if possible th...

Page 30: ...hould now show 0 5 Volt which is equal to 0Mpa 0bar 6 When cranking the engine read the voltage value on the multimeter and look in the table which pres sure the voltage equals NOTE To activate injection a rail pressure of at least 25 MPa 250 bar is demanded 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 0 225 0 270 0 315 0 360 0 405 0...

Page 31: ...esignates a parameter value to which the fault code relates oil pressure for example PPID Proprietary PID The same as the PID but this is a Volvo specific parameter SID Subsystem Identification Description The SID consists of a number that designates a component to which the fault code relates injector for example PSID Proprietary SID The same as the SID but this is a Volvo specific component FMI ...

Page 32: ...10 Mechanical or electrical fault Abnormally large variations 11 Unknown fault Unidentified fault 12 Component fault Faulty unit or component 13 Faulty calibration Calibration values outside the limits 14 Unknown fault Special instructions 15 Data valid but above normal operating range least severe level 16 Data valid but above normal operating range moderately severe level 17 Data valid but above...

Page 33: ...an active inactive fault code Remove the connector from the sensor Check that there is no oxidation and that the connector pins are not damaged If there is a fault please refer to the instructions in chapter Fault tracing of cables and connec tors NOTE Some fault codes become inactive when the engine is stopped Start the engine to check whether the fault code is still inactive with the engine runn...

Page 34: ... The CAN bus consists of a pair of copper conductors which are twisted 30 times per meter The nodes com municate via the CAN bus and they form a network to gether which exchanges information and benefits from each other s services The CAN bus is a serial bus and is the primary control bus J1587 The communication bus J1587 is also used for ac cessories and for diagnostics This is a serial bus in ac...

Page 35: ...istance is less than infinite there is a fault Measuring the engine cables Two types of measurement are done on the engine cable harness both resistance measurement and volt age measurement The measurements are done to ensure that no open circuits or short circuits occur If there is an open circuit the resistance is infinite and if there is a short circuit it is close to zero The resistance values...

Page 36: ...r voltage FMI 5 The current is less than the normal value or is open circuited FMI Fault code explanation 3 4 5 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 5 4 Value fault None Symptom FMI 3 5 Preheat relay never activated White smoke for cold start Start problems in cold climate FMI 4 Induction air is hot Prehea...

Page 37: ...ter its potential and the relay activates B7 is a sense cable which senses that the voltage supply to the preheater is cor rect Fault tracing FMI 3 Abnormally high voltage or short circuit to higher voltage Possible reason Short circuit to B in cable harness between EMS 2 and preheat relay Suitable action 1 Check cable harness and connectors between EMS 2 and preheat relay pre heat relay FMI 4 Abn...

Page 38: ... If any of the measurements shows an abnor mal value check the wiring to and from the engine control unit and the preheat relay Checking the wiring 1 NOTE Cut the current with the main switch 2 Remove connector B from the EMS 2 3 Connect the B connector to brakeout cable 9990014 with measurebox 9998699 4 Use multimeter 9812519 to do a resistance mea surement Measurement points on box Nominal value...

Page 39: ... Engine control unit FMI 1 The sensor value is valid but below the nor mal working range FMI 3 The voltage exceeds the normal value or is short circuited to higher voltage FMI 5 The current is less than the normal value or is open circuited FMI 7 Mechanical fault The system responds in correctly FMI Fault code explanation 1 Fuel pressure is too low 3 5 Faulty sensor Faulty sensor circuit 7 Fuel pr...

Page 40: ... pressure see workshop man ual 7 Check fuel feed pump 8 Change fuel pressure release valve see work shop manual FMI 3 Abnormally high voltage or short circuit to higher voltage 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 volt age or to battery voltag...

Page 41: ...act pres sure 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 FMI 7 Critically low pressure Conditions for fault code The fuel pressure alarm depends on the engine revolu tion Suitable action 1 Check fuel level 2 Open all fuel cocks and check that no leakage oc curs 3 Check drivebelt adjustment 4 Chang...

Page 42: ...he engine control unit Use multimeter 9812519 for voltage measure ment Turn ignition on Measurement points Nominal value 1 4 U 5V Negative cable NOTE Cut the current with the main switch Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control unit...

Page 43: ...m the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control unit Measurement points Nominal value 4 2 R 80 120 kΩ NOTE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit ...

Page 44: ...and the engine control unit Use multimeter 9812519 for voltage measure ment Turn ignition on Measurement points Nominal value 4 2 U 0 5 V at normal atmo spheric pressure Component specification Working range 0 7 bar 0 700 kPa Supply voltage 5 00 0 25 VDC Nominal output voltage at 25 C and at supply voltage 5 00 VDC 0 5 VDC at 0 bar 0 kPa 4 5 VDC at 7 bar 700 kPa Output voltage V Fuel pressure kPa ...

Page 45: ... monitor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 9 Value fault 2 1 Symptom None Circuit description A monitor is located in the water trap under the fuel fil ter Its task is to detect whether there is water in the fuel The monitor senses the resistance between two pins wich are in contact with the fuel When there is no wa ter in the f...

Page 46: ...8 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 wa ter in fuel monitor and EMS 2 FMI 4 Conditions for fault code The voltage signal on B8 is too low Possible reason Short circuit between both cables to the water in fuel monitor The cable connected to B8 is short circuited to battery negative ...

Page 47: ... cable NOTE Cut the current with the main switch Disconnect the connector from the monitor Use multimeter 9812519 to do resistance mea surement against the engine control unit Measurement points Nominal value Black conductor R 0 Ω Battery negative Checking water in fuel monitor 1 Disconnect the connector to the water in fuel mon itor 2 Use multimeter 9812519 to do a resistance mea surement towards...

Page 48: ...alue or is short circuited to higher voltage FMI 5 The current is less than the normal value or is open circuited FMI Fault code explanation 1 Oil pressure is too low 3 5 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 1 Value fault 6 6 Symptom FMI 1 Power is reduced due to error torque map if engine protection par...

Page 49: ... FMI 1 Oil pressure is too low Conditions for fault code Oil pressure depends on the engine revolution Oil pressure exceeds the set value of the engine protec tion 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 filte...

Page 50: ...ssure sensor FMI 5 Abnormally low current or open circuit 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 sen sor Short circuit between signal cable and battery negative to oil pressure sensor Faulty sensor Suitable action 1 Check contact pr...

Page 51: ...ntrol unit Use multimeter 9812519 for voltage measurement NOTE Turn ignition on Measurement points Nominal value 1 3 U 5 V Negative cable NOTE Cut the current with the main switch Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control unit Measur...

Page 52: ...m the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control unit Measurement points Nominal value 2 3 R 80 120 kΩ NOTE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit ...

Page 53: ...VDC 0 5 VDC at 0 bar 0 kPa 4 5 VDC at 7 bar 700 kPa Checking the oil pressure sensor NOTE Turn ignition off Disconnect the connector from the sensor Connect adapter cable 885675 between the sen sor and the engine control unit Use multimeter 9812519 for voltage measurement Turn ignition on Measurement points Nominal value 2 3 U 0 5 V at normal atmospheric pres sure Output voltage V Oil pressure kPa...

Page 54: ...lue or is short circuited to lower voltage FMI 5 The current is less than the normal value or is open circuited FMI Fault code explanation 0 Boost temperature is too high 4 5 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 2 Value fault 6 2 Symptom FMI 0 Engine is derated if engine protection pa rameter is activate...

Page 55: ...e thermistor resistance is high and the EMS 2 senses a high voltage drop As the boost air warms up the resistance in the ther mistor falls and the voltage drop across it falls Fault tracing FMI 0 Boost temperature is too high Conditions for fault code Boost temperature exceeds the set value of the en gine protection parameter Possible reason Engine temperature is too high High surrounding temperat...

Page 56: ...erature sensor FMI 5 Abnormally low current or open circuit 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 boost 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 ...

Page 57: ...he engine control unit Use multimeter 9812519 for voltage measure ment Turn ignition on Measurement points Nominal value 1 2 U 5 V Negative cable NOTE Cut the current with the main switch Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control uni...

Page 58: ...ess connector to the engine control unit Remove connector A from the engine control unit Use multimeter 9812519 to do a resistance mea surement against the engine control unit connec tor A Measurement points Nominal value 2 885675 47 EMS 2 conn A R 0 Ω 2 885675 11 EMS 2 conn A R Ω 1 885675 47 EMS 2 conn A R Ω 1 885675 11 EMS 2 conn A R 0 Ω NOTE Measurement is done to eliminate short circuit ing or...

Page 59: ...75 to the sensor Do not connect the other end of the adapter cable Use multimeter 9812519 to do resistance mea surement Measurement points Nominal value 1 2 R 9426 Ω 470 Ω at 10 C 1 2 R 5896 Ω 332 Ω at 0 C 1 2 R 2511 Ω 109 Ω at 20 C 1 2 R 1200 Ω 47 Ω at 40 C 1 2 R 612 Ω 22 Ω at 60 C 1 2 R 329 Ω 11 Ω at 80 C 1 2 R 186 Ω 5 Ω at 100 C 1 2 R 110 Ω 4 Ω at 120 C ...

Page 60: ...ge FMI 5 The current is less than the normal value or is open circuited FMI Fault code explanation 0 Boost pressure is too high 3 5 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 4 Value fault 3 5 Symptom FMI 0 Power is reduced due to error torque map if engine protection parameter is activat ed FMI 3 5 Pressure s...

Page 61: ...a voltage signal that is proportional to the boost pressure Fault tracing FMI 0 Boost pressure is too high Conditions for fault code Boost pressure exceeds the set value of the engine protection parameter Possible reason The wastegate does not function properly Faulty boost pressure sensor Wrong turbo compressor unit according to the en gine specification Suitable action 1 Check wastegate function...

Page 62: ...on of boost pressure sensor FMI 5 Abnormally low current or open circuit 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 boost pressure signal cable An open circuit in sensor negative cable Short circuited boost pressure signal cable to sen sor negative cable Faulty sensor Suitable action 1 Check contact pressure in socket 22 ...

Page 63: ... control unit Use multimeter 9812519 for voltage measurement Turn ignition on Measurement points Nominal value 1 3 U 5 V Negative cable NOTE Cut the current with the main switch Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control unit Measurem...

Page 64: ...m the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control unit Measurement points Nominal value 4 1 R 80 120 kΩ NOTE Measurement is done to eliminate short circuit ing or breaks in the cable to the engine control unit ...

Page 65: ...er 9812519 for voltage measure ment Turn ignition on Measurement points Nominal value 1 4 U 1 1 V at normal atmospheric pressure Component specification Working range 0 5 4 0 bar 50 400 kPa Supply voltage 5 00 0 25 VDC Nominal output voltage at 25 C and at supply voltage 5 00 VDC 0 5 VDC at 0 5 bar 50 kPa 4 5 VDC at 4 bar 400 kPa Output voltage V Boost air pressure absolute pressure kPa ...

Page 66: ...ort circuited to higher voltage FMI 4 The voltage is less than the normal value or is short circuited to lower voltage FMI Fault code explanation 2 Plausibility 3 4 Faulty sensor Faulty sensor circuit Fault indication DCU None CIU None Flash code Electrical fault None Value fault None Symptom FMI 3 4 Ambient pressure is set to 1 0 bar Component description Sensor is placed inside the engine contro...

Page 67: ...Group 30 Electrical system Diagnostic Trouble Codes 65 Fault tracing FMI 2 3 4 Conditions for fault code Internal fault in the engine control unit Suitable action 1 Replace the engine control unit EMS 2 ...

Page 68: ... age FMI 5 The current is less than the normal val ue or is open circuited FMI Fault code explanation 0 Coolant temperature too high 4 5 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 3 Value fault 6 1 Symptom FMI 0 Engine is derated if engine protection parameter is activated FMI 4 5 Engine is difficult to start ...

Page 69: ...temperature is too high 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...

Page 70: ... 2 2 Check function of coolant temperature sensor FMI 5 Abnormally low current or open circuit 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 sen sor Open circuit in negative cable to temperature sen sor Faulty sensor Suitable action 1 Check contact pressure in socket 18 and 27 in engine connector B C...

Page 71: ... engine control unit Use multimeter 9812519 for voltage measure ment NOTE Turn ignition on Measurement points Nominal value 1 2 U 5 V Negative cable NOTE Cut the current with the main switch Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control ...

Page 72: ... ness connector to the engine control unit Remove connector B from the engine control unit Use multimeter 9812519 to do a resistance mea surement against the engine control unit connec tor B Measurement points Nominal value 2 885675 27 EMS 2 conn B R 0 Ω 2 885675 18 EMS 2 conn B R Ω 1 885675 27 EMS 2 conn B R Ω 1 885675 18 EMS 2 conn B R 0 Ω NOTE Measurement is done to eliminate short circuiting o...

Page 73: ...675 to the sensor Do not connect the other end of the adapter ca ble Use multimeter 9812519 to do resistance mea surement Measurement points Nominal value 1 2 R 9397 Ω 755 Ω at 10 C 1 2 R 5896 Ω 430 Ω at 0 C 1 2 R 2500 Ω 148 Ω at 20 C 1 2 R 1175 Ω 56 Ω at 40 C 1 2 R 596 Ω 22 Ω at 60 C 1 2 R 323 Ω 10 Ω at 80 C 1 2 R 186 Ω 5 Ω at 100 C 1 2 R 113 Ω 4 Ω at 120 C ...

Page 74: ...ltage exceeds the normal value or is short circuited to higher voltage FMI Fault code explanation 1 Coolant level is too low 3 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 3 Value fault 2 2 Symptom FMI 1 VE engines Engine is derated if engine protection pa rameter is activated GE engines Engine is shutdown ...

Page 75: ...ant level falls the float operates the switch and a closed circuit is formed Fault tracing FMI 1 Coolant level is too low Suitable action 1 Check coolant level 2 Bleed coolant water system 3 If low coolant level check coolant water system for leakage by a pressure test 4 Check pressure valve in the coolant cup or try with another coolant cup 5 Check wiring to the coolant level switch 6 Check funct...

Page 76: ...nt NOTE Turn the ignition on Measurement points Nominal value 1 2 U Battery voltage x 0 8 Negative cable NOTE Cut the current with the main switch Disconnect the connector from the level switch Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control unit Measurement points Nominal value ...

Page 77: ...ant 1 Undo the connector and remove the level switch from the expansion tank 2 Use multimeter 9812519 to do resistance mea surement against the switch Measurement points Nominal value Blue Black R Ω 3 Move a magnet along the monitor and observe the resistance value The resistance should drop to approx 0 Ohm Measurement points Nominal value Blue Black R 0 Ω ...

Page 78: ...I 1 The sensor value is valid but below the nor mal working range FMI Fault code explanation 1 Bellow range Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault None EMS Value fault 3 9 EMS Electrical fault None CIU Value fault 6 9 CIU Symptom Could be engine starting problems ...

Page 79: ...orking range Possible reason Battery voltage less than 24 1V Possible reason Altenator belt Flat poor batteries Fault in cables or connectors for battery alterna tor Faulty altenator Suitable action 1 Check battery cables and connections 2 Check charge batteries 3 Check altenator and drive belt ...

Page 80: ...he current is less than the normal value or is open circuited FMI Fault code explanation 0 Sensor out of range 2 Plausibility 4 5 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU None Lamp status FMI 0 None FMI 2 4 5 Yellow lamp Flash code Electrical fault 8 3 Value fault None Symptom FMI 2 4 5 Engine speed limitation 1100rpm Full fuel flow delivery limp h...

Page 81: ...al that is proportional to the rail pressure Fault tracing FMI 0 Rail pressure is too high Conditions for fault code Rail pressure depends on engine revolution and en gine load Possible reason Faulty MROP Faulty rail pressure sensor Suitable action 1 Check MPROP cables and connectors 2 Check function of rail pressure sensor FMI 2 Conditions for fault code Plausibility fault Possible reason Faulty ...

Page 82: ...nt or open circuit 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 sup ply cable Faulty rail pressure sensor Su...

Page 83: ...he engine control unit Use multimeter 9812519 for voltage measure ment Turn ignition on Measurement points Nominal value 1 3 U 5V Negative cable NOTE Cut the current with the main switch Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control unit...

Page 84: ... the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 to do resistance mea surement against the engine control unit Measurement points Nominal value 1 2 R 4 0 5 0 kΩ NOTE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit ...

Page 85: ...en the sen sor and the engine control unit Use multimeter 9812519 for voltage measure ment Turn ignition on Measurement points Nominal value 1 2 U 0 5 V at normal atmospheric pressure Component specification Working range 0 1800 bar 0 180 MPa Supply voltage 5 00 0 25 VDC Nominal output voltage at 25 C and at supply voltage 5 00 VDC 0 5 VDC at 0 bar 0 kPa 4 5 VDC at 1800 bar 180 MPa ...

Page 86: ...mal working range FMI Fault code explanation 0 Engine is was overspeeding Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault None Value fault 2 6 Symptom Engine speed limited Fault tracing FMI 0 Possible reason Too high engine speed Suitable action 1 After the engine has stopped search for the rea son for the high speed ...

Page 87: ...age FMI 4 The voltage is less than the normal value or is short circuited to lower voltage FMI Fault code explanation 3 4 Faulty circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 4 7 EMS Value fault None EMS Electrical fault 5 2 CIU Value fault None CIU Symptom FMI 3 The engine starts cranking immediately when ignition is turned on FMI 4 The engi...

Page 88: ... and connectors between CIU and start switch 3 Check function of start switch FMI 4 Abnormally low voltage or short circuit to lower voltage 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 bet...

Page 89: ...e is less than the normal value or is short circuited to lower voltage FMI 5 The current is less than the normal value or is open circuited FMI Fault code explanation 3 4 5 Faulty circuit Fault indication DCU Engine warning in DCU display CIU Flash code 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 u...

Page 90: ...4 Check function of aux stop button at EMS stop button at CIU FMI 4 Abnormally low voltage or short circuit to lower voltage 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 FMI 5 Abnormally low current or open circuit Possible reason An o...

Page 91: ... short circuited to battery negative FMI 5 The current is less than the normal value or is open circuited FMI 7 Mechanical fault The system responds in correctly FMI Fault code explanation 3 4 5 Faulty sensor Faulty sensor circuit 7 Mechanical fault Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault 8 5 Value fault None Symptom FMI 3 4 5 IEGR can not be turned ...

Page 92: ...vate the exhaust gas recirculation function The solenoid is activated when pin B30 on the EMS 2 changes its po tential Fault tracing FMI 3 Abnormally high voltage or short circuit to higher voltage 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 FMI 4 Abnormally low voltage or short ci...

Page 93: ...itable action 1 Check function of IEGR solenoid 2 Check engine oil pressure Measurements NOTE If any of the measurements shows an abnor mal value check the wiring to and from the engine in terface Checking the wiring 1 NOTE Cut the current with the main switch 2 Remove the connector to the IEGR solenoid 3 Remove connector B from the EMS 2 4 Connect the B connector to brakeout cable 9990014 with me...

Page 94: ... resis tance in the IEGR coil Measurement points Nominal value 1 2 R 28 42 Ω Checking IEGR solenoid 1 NOTE Cut the current with the main switch 2 Remove the IEGR solenoid Please see the workshop manual for TAD650 760VE Group 21 26 for reference how to remove the IEGR solenoid 3 Connect a 24 volt power supply to the IEGR elec trical connection The solenoid should now make a click when alter its pos...

Page 95: ...ange FMI 4 The voltage is less than the normal value or is short circuited to lower voltage FMI 5 The current is less than the normal value or is open circuited FMI Fault code explanation 0 ECU temperature is too high 4 5 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault 8 4 Value fault None Symptom None ...

Page 96: ...urrounding temperature Fault in sensor Suitable action 1 Check if the surrounding temperature is high or if the EMS 2 unit is exposed to heat radiation 2 Change EMS 2 unit FMI 4 The voltage is less than the normal value or is short circuited to lower voltage Possible reason Fault in sensor circuit Suitable action 1 Change EMS 2 unit FMI 5 Abnormally low current or open circuit Possible reason Faul...

Page 97: ... PPID 98 Engine sync acknowledge MID 128 Engine control unit FMI 9 Abnormal updating frequency on the sec ondary bus FMI Fault code explanation 9 Communication fault Fault indication DCU Engine warning in DCU display CIU Flashcode Flash code Electrical fault None ...

Page 98: ...ODIA and that is normal FMI 9 Fault condition Time out on the J1587 bus Possible reason Fault in the communication with the DCU CIU No DCU CIU found Open circuit in the power supply cable between the engine control unit and the DCU CIU Faulty DCU CIU Suitable action 1 Check communication cables to the DCU CIU 2 Check power supply cable between engine control unit and DCU CIU 3 Check that DCU CIU i...

Page 99: ... the normal value or is short circuited to battery negative FMI 9 Abnormal update rate FMI Fault code explanation 3 4 Faulty throttle potentiometer Faulty throttle potentiometer circuit 9 EMS2 is missing the throttle signal Fault indication DCU Engine warning in DCU display CIU Flashcode Flash code Electrical fault 2 8 Value fault None Symptom Engine goes to idle If the accelerator is released at ...

Page 100: ...e 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 Abnormally low voltage or short circuit to lower voltage Possible reason Short circuited throttle...

Page 101: ...entiometer 3 Check function of throttle potentiometer 4 Check contact pressure in socket 2 3 and 30 in CIU connector Logging throttle signal with Vodia To verify the throttle signal on the J1587 bus do as follow 1 Choose Log test under the Service and mainte nance meny 2 Choose MID 128 Accelerator Pedal Position and MID 144 Throttle Calibrated Position and press play 3 Verify that booth throttle v...

Page 102: ...h volt age side FMI 5 Break in injector circuit FMI 7 Mechanical fault The system responds in correctly FMI 12 Low injector hold current FMI 14 Special instructions FMI Fault code explanation 3 4 5 7 12 Fault in the injection system Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 7 1 7 6 Value fault None Symptom FMI 3 4 5 Faulty injector is shut off Li...

Page 103: ... FMI 3 Checking injector circuit 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 side Short circuit to battery voltage in low voltage in jector wire Suitable action 1 Check c...

Page 104: ...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 sid...

Page 105: ...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 FMI 12 Checki...

Page 106: ...s NOTE If any of the measurements shows an abnor mal value check the wiring to and from the engine in terface NOTE Cut the current with the main switch Remove both wires that are connected to the in jector that is to be measured Remove connector A from the EMS 2 Use multimeter 9812519 to do a resistance mea surement between connector A from the EMS 2 to the loosened wires from the injector See cir...

Page 107: ...ermittent or faulty data FMI 3 No signal FMI 8 Abnormal frequency FMI Fault code explanation 2 3 8 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 5 Value fault None Symptom FMI 2 3 8 The engine start time will increase uses only crankshaft sensor ...

Page 108: ... turn for injection Fault tracing FMI 2 Checking sensor circuit 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 pre...

Page 109: ...heck 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 FMI 8 Checking sensor circuit 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 Chec...

Page 110: ...n switch Remove the connector from the sensor Connect adapter cable 885675 to the connector Remove connector A from the EMS 2 Use multimeter 9812519 to do a resistance mea surement from the sensor connector to connector A to verify that neither of the wires are broken or short circuited Measurement points Nominal value 1 sensor conn 46 conn A R 0 Ω 2 sensor conn 45 conn A R 0 Ω 1 sensor conn 2 sen...

Page 111: ...75 to sensor NOTE Do not connect the other end of the adapter cable to the engine cable harness since this can cause a measurement error 4 Use multimeter 9812519 for resistance measure ment Measurement points Nominal value 1 2 R 3 5 kΩ at 20 C NOTE The measurement must exclude short circuit or open circuit to the engine control unit 5 Use multimeter 9812519 for a AC voltage mea surement Move a met...

Page 112: ...MI Fault code explanation 2 3 8 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 4 Value fault None Symptom FMI 3 Engine is running with imprecise timing causing risk of high fuel consumption and smoke Cylinder balancing not working with risk of uneven running FMI 2 8 Engine is difficult to start uses only cam senso...

Page 113: ...ecognize the position of the crankshaft Fault tracing FMI 2 Checking sensor circuit Conditions for fault code Incorrect signal Possible reason Short circuit between cables to speed sensor Polarity fault The cables to the speed sensor is shifted Suitable action 1 Check cable harness and connectors between speed sensor and EMS 2 2 Check that speed sensor is connected as in the circuit description 3 ...

Page 114: ...S 2 2 Check contact pressure in socket 37 and 38 in engine connector A 4 Check installation of speed sensor 5 Check function of speed sensor FMI 8 Checking sensor circuit Conditions for fault code Incorrect speed sensor signal Possible reason Incorrectly mounted speed sensor Electrical interference in the sensor signal Suitable action 1 Check wiring and connectors between speed sen sor and EMS 2 2...

Page 115: ...onnector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Remove connector A from the EMS 2 Use multimeter 9812519 to do a resistance mea surement from the sensor connector to connector A to verify that neither of the wires are broken or short circuited Measurement points Nominal value 1 sensor conn 38 conn A R 0 Ω 2 sensor conn 37 conn A R 0 ...

Page 116: ...o the connector from the sensor and remove the sensor from the cylinder head Check that the sensor does not have any external damage or any swarf which has got stuck on it 3 Connect adapter cable 885675 to sensor NOTE Do not connect the other end of the adapter cable to the engine cable harness since this can cause a measurement error 4 Use multimeter 9812519 for resistance measure ment Measuremen...

Page 117: ...xceeds the normal value or is short circuited to higher voltage FMI 4 The voltage is less than the normal value or is short circuited to lower voltage FMI 5 The current is less than the normal value or is open circuited FMI Fault code explanation 3 4 5 Fault in starter relay circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault 4 6 Value fault None Symptom...

Page 118: ...ery 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 FMI 4 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...

Page 119: ... Measurements Checking starter relay coil 1 NOTE Cut the current with the main switch 2 Remove one of the wires to the starter relay 3 Use multimeter 9812519 to measure the resis tance in the coil Measurement points Nominal value Relay connectors R 9 15 Ω Checking starter relay voltage supply 1 Turn ignition off 2 Connect multimeter 9812519 to do a voltage mea surement over the starter relay 3 Tur...

Page 120: ...e FMI 5 The current is less than the normal value or is open circuited FMI 6 The current is greater than the normal value or is short circuited to battery negative FMI 13 Calibration value of range FMI Fault code explanation 3 4 5 6 13 Faulty regulator Faulty regulator circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault 8 3 Value fault None Symptom All F...

Page 121: ...e current to the valve solenoid rises the less fuel pres sure rail pressure is obtained So if a wire breaks full fuel flow will be achieved Fault tracing FMI 3 Abnormally high voltage or short circuit to higher voltage Possible reason Short circuit to battery voltage in MPROP nega tive cable pin 2 on MPROP Suitable action 1 Check cable harness and connectors between EMS 2 and MPROP FMI 4 Abnormall...

Page 122: ...re in connector at MPROP 2 Check cable harness and connectors between EMS 2 and MPROP FMI 6 The current is greater than the normal value or is short circuited to battery negative Possible reason Short circuit to battery negative in MPROP nega tive 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 co...

Page 123: ...ecking the wiring NOTE Cut the current with the main switch Remove the connector to the MPROP Remove connector A from the EMS 2 Use multimeter 9812519 to do a resistance mea surement against the engine control unit connec tor A Measurement points Nominal value 2 885675 16 EMS 2 conn A R 0 Ω 2 885675 12 EMS 2 conn A R Ω 1 885675 16 EMS 2 conn A R Ω 1 885675 12 EMS 2 conn A R 0 Ω ...

Page 124: ...the normal value or is short circuited to lower voltage FMI 5 The current is less than the normal value or is open circuited FMI Fault code explanation 3 4 5 Faulty relay Faulty relay circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Symptom FMI 3 Fuse for shorting wire breaks FMI 4 Start problems in cold climate FMI 5 Might get s...

Page 125: ... of preheat relay 3 Change heating element FMI 4 Abnormally low voltage or short circuit to lower voltage Possible reason Short circuit to battery negative in sense wire Suitable action 1 Check function of preheat relay 2 Check cable harness and connectors to heating element FMI 5 Possible reason An open circuit in sense wiring Heating element broken Suitable action 1 Check contact pressure in soc...

Page 126: ...xceeds the normal value or is short circuited to higher voltage FMI 4 The voltage is less than the normal value or is short circuited to lower voltage FMI Fault code explanation 3 4 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault 9 3 Value fault None Symptom None ...

Page 127: ...tage and bat tery voltage in EMS 2 connector B Suitable action 1 Check all 5V supply cables distributed by EMS 2 connector B see EMS 2 wiring diagram FMI 4 Abnormally low voltage or short circuit to lower voltage 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 s...

Page 128: ...ermittent or faulty data FMI Fault code explanation 2 Communication fault J 1939 Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 6 5 EMS Value fault None EMS Electrical fault 6 4 CIU Value fault None CIU Symptom Engine can not be started or if engine is running it can only be stopped by pushing the aux stop ...

Page 129: ...to each other CAN H or CAN L short circuited to battery nega tive on pin 3 CAN L short circuited to power supply on pin 4 CAN H or CAN L short circuited to any of the J1708 links Suitable action 1 Check all data links between DCU CIU and EMS 2 CAN H datalink to engine CAN L datalink to engine Power supply Power supply input Ignition Stop J1708A datalink to engine J1708B datalink to engine B55 B51 ...

Page 130: ...r at the DCU 1 2 U 60 Ω or Measurement points Nominal value in the CIU connector 11 12 U 60 Ω NOTE Even if the measured value equals the nomi nal value the data bus cable could be faulty due to shortcircuit between a data bus cable and another ca ble in the harness Connect adapter cable 88890016 with measure box 9998699 between the EMS 2 and the CIU DCU Use multimeter 9812519 to a voltage measure ...

Page 131: ...xceeds the normal value or is short circuited to higher voltage FMI 4 The voltage is less than the normal value or is short circuited to lower voltage FMI Fault code explanation 3 4 Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault 9 3 Value fault None Symptom None ...

Page 132: ...ge and bat tery voltage in EMS 2 connector A Suitable action 1 Check all 5V supply cables distributed by EMS 2 connector A see EMS 2 wiring diagram FMI 4 Abnormally low voltage or short circuit to lower voltage Possible reason Short circuit between the supply cables to the boost pressure sensor Short circuit between the supply cables to the rail pressure sensor Suitable action 1 Check the sensor s...

Page 133: ...uction FMI Fault code explanation 2 7 11 14 Communication fault Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 9 9 Value fault None Symptom The engine can not be started Fault tracing FMI 2 7 11 14 Conditions for fault code Checksum error Possible reason Downloading interrupted Internal fault in the engine control unit Suitable action 1 Reprogram the ...

Page 134: ...component FMI Fault code explanation 3 8 12 Faulty component Fault indication DCU Engine warning in DCU display CIU Flash code 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 Fault tracing FMI 3 8 12 Conditions for fault code Internal fault in the engine control unit Suitable action 1 Replace the engine co...

Page 135: ... FMI Fault code explanation 0 1 4 7 12 Fault in rail pressure circuit Fault indication DCU Engine warning in DCU display CIU None Lamp status FMI 0 12 Yellow lamp FMI 1 4 7 Red lamp Flash code Electrical fault 8 3 Value fault None Symptom FMI 0 Engine derated engine speed limita tion 1100 rpm Full fuel flow delivery Limp home with pressure relief valve opened FMI 1 7 12 Engine derated engine speed...

Page 136: ...tor is faulty FMI 1 Conditions for fault code Rail pressure controller integral part too big High pres sure leakage detected Possible reason High pressure leakage Faulty rail pressure sensor MPROP closed or partly closed or out of charac teristic Rail pressure release valve stuck open or unwant ed opening An injector is stuck open Faulty high pressure pump Suitable action 1 Check fuel pipes for le...

Page 137: ... 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 7 Change MPROP valve 8 Check if an injector is faulty 9 Check both high pressure pumps see workshop manual Group 21 2...

Page 138: ...r partly closed or out of charac teristic Rail pressure release valve stuck open or unwant ed 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 ...

Page 139: ...4 Pressure release valve open Fault indication DCU Engine warning in DCU display CIU None Lamp status FMI 0 11 14 Yellow lamp FMI 7 Red lamp Flash code Electrical fault 8 3 Value fault None Symptom FMI 0 11 Engine derated engine speed limitation 1100 rpm Fuel pressure limitation 800 bar Engine torque reduction FMI 7 Engine shut off after delay or engine derat ed Engine derated engine speed limita ...

Page 140: ...and stage 2 maintains the pressure at about 60 MPa 600 bar 8702 psi If the MPROP valve has been dam aged and gives full flow for example the pressure re lease valve reduces the fuel flow to about 60 MPa 600 bar 8702 psi NOTE MPROP valve Magnetically controlled pro portional valve Fault tracing FMI 0 Conditions for fault code Leakage detected in rail pressure release valve open mode Possible reason...

Page 141: ...ion 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 rail pressure release valve FMI 11 Conditions for fault code High rail pressure when rail pressure release valve is open Possible reason Rail pressure controller out of range Pressure release valve stuck c...

Page 142: ...circuit in one or both cables from EMS 2 to MPROP Short circuit to battery negative in MPROP nega tive cable pin 2 on MPROP MPROP stuck open 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 ...

Page 143: ...ault code explanation 9 Communication error Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Symptom None Component description CAN H datalink to engine CAN L datalink to engine Power supply Power supply input Ignition Stop J1708A datalink to engine J1708B datalink to engine B55 B51 A58 A27 A33 A34 ...

Page 144: ...n 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 be tween 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 v...

Page 145: ...connector at the DCU 1 2 U 60 Ω or Measurement points Nominal value in the CIU connector 11 12 U 60 Ω NOTE Even if the measured value equals the nomi nal value the data bus cable could be faulty due to shortcircuit between a data bus cable and another ca ble in the harness Connect adapter cable 88890016 with measure box 9998699 between the EMS 2 and the CIU DCU Use multimeter 9812519 to a voltage ...

Page 146: ...down after 5 sec after 15 sec High coolant 98 101 101 106 106 106 temperature C High boost 80 83 83 90 90 90 temperature C High boost 340 350 350 355 355 pressure kPa Low oil Limit 20 limit 20 limit 25 limit 25 limit pressure kPa Oil pressure limit Pressure kPa Engine speed rpm Oil pressure limit Engine protection Engine speed rpm Torque Nm TAD 650 660 750 760 VE ...

Page 147: ...lant 98 106 106 temperature C High oil temperature C 125 135 135 High boost 80 90 90 temperature C High boost 340 355 355 pressure kPa Low coolant level switch switch Low oil Limit 25 limit 25 limit pressure kPa Oil pressure limit 0 50 100 150 200 250 300 0 500 1000 1500 2000 2500 Engine speed Oil pressure kpa Oil pressure limit ...

Page 148: ...ply 18 MPROP 19 Rail pressure 20 Boost pressure 21 Speed sensor crankshaft 21 Speed sensor camshaft 22 Boost temperature 24 Injectors 25 Preheat sensor 26 Preheat relay 27 Preheat supply 28 J1939 CAN bus 29 Battery negative 30 Battery plus 31 Ignition 32 Stop 33 J1587 1708 bus 34 Extra stop AUX stop 35 Main relay 36 Connector engine interface 37 Main fuse 10A 38 Battery 24V 39 Coolant level 40 Wat...

Page 149: ...pressure temperature supply 17 Rail pressure supply 18 M PROP 19 Rail pressure 20 Boost pressure 21 Speed sensor crankshaft 22 Speed sensor camshaft 23 Boost temperature 24 Injectors 25 Start motor and prestart relay 26 Internal EGR sensor 27 Coolant temperature sensor 28 Fuel pressure sensor 29 Oil pressure sensor 30 Boost pressure temperature sensor 31 Rail pressure sensor 32 M PROP 33 Speed sen...

Page 150: ...Wiring diagram Group 30 Electrical system 148 EMS 2 engine harness TAD734 GE ...

Page 151: ...SB Black VO Violet W White Y Yellow Cable area 0 75 mm2 unless otherwise specified 1 Stop contact 2 Start contact 3 1 pin connector 4 Horn buzzer alarm 5 Easy Link connector 6 RPM potentiometer 7 Indicator engine operation 8 8 pin connector engine interface 9 8 pin connector engine interface 10 Termination resistance 120 Ohm 11 Display Control unit DCU ...

Page 152: ...erface Unit CIU CIU Cable colors BL Blue LBL Light blue BN Brown LBN Light brown GN Green GR Grey OR Orange P Pink R Red SB Black VO Violet W White Y Yellow Cable area 0 75 mm2 unless otherwise specified 1 Key switch 15 2 RPM potentiometer 3 Tachometer code 14 4 Oil pressure instrument 5 Oil temperature instrument 6 Coolant temperature instrument 7 Instrument illumination 8 Idling contact two way ...

Page 153: ...nsor camshaft Speed sensor crankshaft Connector 3 pin Working temperature range 40 C to 130 C Type Inductive sensor Max tightening torque 8 2 Nm 6 1 5 lbf ft Sensor oil pressure Voltage 5 V Connector 3 pin Working pressure range 0 700 kPa 0 7 bar Pressure signal 0 5 4 5 V Working temperature range 40 C to 140 C Type Linear Max tightening torque 30 5 Nm 22 3 7 lbf ft Sensor rail pressure Voltage 5 ...

Page 154: ...e signal 0 5 4 5 V Working temperature range 40 C to 130 C Type Linear NTC Sensor coolant temperature Voltage 5 V Connector 2 pin Type NTC Max tightening torque 25 Nm 18 4 lbf ft Switch coolant level Connector 2 pin Contact type Closing with low coolant level Alternator Voltage 28V Connector 2 pin Capacity 80 A at 28V Starter motor Voltage 24 V Connector 1 pol Capacity 5 5 kW ...

Page 155: ...ne speed 190 2 6 190 0 84 Engine starter relay 677 1675 4 6 39 3 4 5 115 Engine stop switch 520195 4 8 EMS 6 3 4 5 87 970 5 3 CIU Engine sync acknowledge 608 98 9 95 Injection control pressure regulator 679 8 3 42 3 4 5 6 13 118 Injector common rail 1 6 651 656 7 1 7 6 1 6 3 4 5 7 12 100 Internal EGR status 8 5 19 3 4 5 7 89 Inlet air heater status 626 5 4 45 3 4 5 33 J 1939 communication bus 639 ...

Page 156: ...FMI Please refer Electrical fault to page value fault Speed sensor crankshaft 637 2 4 22 2 3 8 110 Starter input CIU 4 7 5 2 4 3 4 85 Throttle input request failure DCU CIU 608 2 8 132 3 4 9 97 Water in fuel 97 2 9 2 1 97 0 4 43 5V sensor supply 1 620 9 3 232 3 4 129 5V sensor supply 2 9 3 211 3 4 124 ...

Page 157: ...155 References to Service Bulletins Group No Date Refers to Group 30 Electrical system References to Service Bulletins ...

Page 158: ...Notes ...

Page 159: ... this page write your comments down and send them to us The address is at the bottom We would prefer you to write in English or Swedish From Refers to publication Publication No Date of issue Proposal motivation Date Signed AB Volvo Penta Technical Information Dept 42200 SE 405 08 Göteborg Sweden ...

Page 160: ...7747632 English 03 2007 ...

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