workshop manual gp.30 volvo penta tad760ve .pdf

8/19/2019 Workshop Manual Gp.30 Volvo Penta TAD760VE .pdf

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Workshop Manual

Group 30

TAD650VE, TAD660VE,

TAD734GE, TAD750VE, TAD760VE

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Group 30 Electrical system

Industrial Engines

TAD734GE, TAD650VE, TAD660VE, TAD750VE,

TAD760VE

ContentsSafety rules............................................................ 3

General information .............................................. 4About this Workshop Manual ............................... 4

Spare parts .......................................................... 4

Certified engines .................................................. 4

Repair instructions................................................ 5

Our common responsibility ................................... 6

Tightening torques ............................................... 6

Special tools ......................................................... 7

EMS 2 - “Engine Management System” .............. 8General information .............................................. 8

CAN - Controller Area Network ............................. 8

CIU - Control Interface Unit .................................. 9

DCU - Display Control Unit ................................... 9

Fuel control ........................................................ 10

Calculation of fuel quantity ................................. 10

Altitude correction .............................................. 10

Diagnostic function ............................................ 10

Component location ........................................... 11

TAD 650, 660, 750, 760 VE ............................... 11TAD 734 GE ...................................................... 12

Component description ...................................... 13

Starter motor ...................................................... 13

Alternator ........................................................... 13

Injectors ............................................................. 14

Speed sensor, crankshaft .................................. 14

Speed sensor, camshaft .................................... 14

Sensor, boost pressure/ boost temperature .............................................. 15

Sensor, oil pressure, engine ............................... 15

EGR................................................................... 15

Coolant temperature sensor ............................... 16

Sensor, common rail pressure (fuel)................... 16

Sensor, fuel pressure ......................................... 16

Magnetically controlled proportional valve(MPROP) ........................................................... 17

Water in fuel switch, secondary fuel filter .......... 17

Switch, coolant level .......................................... 17

Preheater ........................................................... 18

Engine control unit, EMS 2 ................................ 18

Repair instructions.............................................. 19

General advice on working with EMS engines .... 19

Electric welding .................................................. 20

Changing the engine control unit ........................ 21

Reprogramming a control unit............................. 22Programming an empty control unit .................... 23

Fault tracing of cables and connectors............... 24

Checking the starter motor voltage..................... 26

Checking the charging system ........................... 27

Rail pressure measurement................................ 28

Malfunctions........................................................ 29Fault code information........................................ 29

FMI table / SAE standard .................................. 30

Manual fault tracing in bus cables ...................... 33

Diagnostic Trouble Codes .................................. 34

MID 128, PID 45Inlet air heater status ......................................... 34

MID 128, PID 94Fuel pressure ..................................................... 37

MID 128, PID 97Water in fuel....................................................... 43

MID 128, PID 100Oil pressure ....................................................... 46

MID 128, PID 105Boost temperature ............................................. 52

MID 128, PID 106Boost pressure................................................... 58


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© 2007 AB VOLVO PENTAWe reserve the right to make modifications without prior notice.

Printed on environmentally compatible paper.

MID 128, PID 108Ambient air pressure .......................................... 64

MID 128, PID 110Coolant temperature ........................................... 66

MID 128, PID 111Coolant level ...................................................... 72

MID 128, PID 158

Battery voltage................................................... 76MID 128, PID 164Rail pressure ...................................................... 78

MID 128, PID 190Engine speed ..................................................... 84

MID 128 / MID 144, PPID 4Start input CIU ................................................... 85

MID 128 / MID 144, PPID 6Engine stop switch ............................................. 87

MID 128, PPID 19Internal EGR status ........................................... 89

MID 128, PPID 55EMS temperature ............................................... 93

MID 128, PPID 98Engine sync acknowledge.................................. 95

MID 128 / 144, PPID 132

Throttle input request failure, DCU/CIU .............. 97

MID 128, SID 1-6Injector common rail # 1-6 ................................. 100

MID 128, SID 21Speed sensor camshaft ....................................105

MID 128, SID 22Speed sensor, crankshaft .................................110

MID 128, SID 39Engine starter relay ........................................... 115

MID 128, SID 42Injection control pressure regulator....................118

MID 128, SID 70Preheat sense................................................... 122

MID 128, SID 2115V sensor supply 2 ........................................... 124

MID 128, SID 231Communication fault J 1939.............................. 126

MID 128, SID 2325V sensor supply 1 ........................................... 129

MID 128, SID 240Program memory .............................................. 131

MID 128, SID 254Controller error .................................................. 132

MID 128, PSID 96Rail pressure system ........................................ 133

MID 128, PSID 97Rail pressure release valve ............................... 137

MID 128 / MID 144, PSID 201

J1939 communication bus ................................141

Engine protection ..............................................144TAD 650, 660, 750, 760 VE ..............................144

TAD 734 GE .....................................................145

Wiring diagrams.................................................146

Wiring diagram EMS 2: Vechicle harness TAD 650-760VE ................... 146 Engine harness TAD 650-760VE...................... 147

Engine harness TAD 734GE ............................ 148

Wiring diagram DCU ..........................................149Wiring diagram CIU ........................................... 150

Technicaldata .................................................... 151

Switch, water in fuel ..........................................151

Sensor, fuel pressure ........................................ 151

Speed sensor, camshaft / Speed sensor, crankshaft .................................151

Sensor, oil pressure .......................................... 151

Sensor, rail pressure ......................................... 151

Combination sensor,boost pressure/boost temperature ..................... 152

Sensor, coolant temperature .............................152

Switch, coolant level ......................................... 152

Alternator .......................................................... 152

Starter motor ..................................................... 152

Index ...................................................................153

References to Service Bulletins ........................ 153


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Group 30: Electrical system Safety information

3

Safety rules

Introduction

This workshop manual contains technical data, de-

scriptions and repair instructions for the Volvo Pentaproducts or product versions noted in the table of con-tents. Check that you have the correct WorkshopManual for your engine.

Read the available safety information, ”General infor-mation” and ”Repair instructions” in this workshopmanual before you start to do any service work.

Never do any work on an engine which justhangs from a lifting device (crane etc.).

The engine must not be run in areas where ex-plosive material or any gases are stored.

Only start the engine in a well-ventilated area. Ifthe engine is run in a confined space, makesure that the crankcase ventilation and exhaustgases can be led away from the workplace.

The battery lockers must never be exposed toopen flames or sparks. Never smoke close tothe batteries. The batteries generate hydrogengas when charged, which can form an explosivegas when mixed with air. This gas mixture isvery flammable and highly explosive. A spark,which can be caused by incorrect battery con-nection, can cause a single spark which is suffi-cient to cause an explosion with resulting dam-age. Do not shift the connections when attempt-ing to start the engine (spark risk) and do notlean over any of the batteries. Please refer tothe advice in the instruction book.

Always ensure that the + (positive pole) and –(negative pole) are securely connected to their

appropriate terminals on the battery. If the bat-teries are wrongly connected, this can causesevere 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 batteryacid comes into contact with your skin, wash itoff at once with a lot of soap and water, andthen get medical help. If battery acid comesinto contact with your eyes, flush your eyes at

once (preferably with an eye shower) with a lotof clean water, and then get medical help atonce.

Important!

The following special warning symbols occur in thisbook and on the engine.

WARNING! Warns for the risk of personal injury,property damage or that a mechanical fault canoccur if the instructions are not followed.

IMPORTANT! Is used to call attention to thingswhich could cause damage or malfunctions toproduct or property.

NOTE! Is used to call attention to important informa-

tion, to facilitate work processes or operation.

Below is a summary of the risks involved and safetyprecautions you should always observe or carry outwhen performing work on the EMS 2 system.

Before electric welding is done, the connectoron the EMS system must be disconnected.Disconnect the engine from system voltage byturning off the main switch.Disconnect the cable connectors from the con-trol unit.

Reconnect the EMS 2 control module terminalwhen the electric welding is finished and the elec-tric welding equipment has been disconnected.

Be careful, watch out for the moving compo-nents of the engine during function testing andin operation. Approaching the engine during op-eration entails a risk of personal injury. Remem-ber that loose clothes or long hair can catch onrotating components and cause severe injury.


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4

General information

About this Workshop ManualThis workshop manual contains descriptions and re-

pair instructions for the standard versions of theTAD734GE, TAD650VE, TAD660VE, TAD750 andTAD760VE engines.

The workshop manual can illustrate tasks done onany of the engines noted above. This means that theillustrations and photographs which clarify certain de-tails might not correspond with other engines in somecases. Repair methods are similar in all important re-spects, however. If this is not the case, this is noted.Important differences are noted separately.

The engine designation and number are noted on thenumber plate and engine decal. The engine designa-

tion and number must always be given in all corre-spondence about any product.

The workshop manual is produced primarily for theuse of Volvo Penta workshops and service techni-cians. For this reason the manual presupposes a cer-tain basic knowledge and that the user can carry outthe mechanical/electrical work described to a generalstandard of engineering competence.

Volvo Penta constantly improves its products, so wereserve the right to make modifications without priornotification. All information in this manual is based onproduct data which was available up to the date on

which the manual was printed. Any material changesintroduced into the product or service methods afterthis date are notified by means of Service Bulletins.

Spare partsSpare parts for electrical and fuel systems are subjectto various national safety requirements. Volvo PentaOriginal Spare Parts meet these specifications. Anykind of damage whatsoever, occasioned by use ofnon-original Volvo Penta spares for the product inquestion, 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 to be aware of the fol-lowing:

Certification means that an engine type has beenchecked and approved by the relevant authority. Theengine manufacturer guarantees that all engines madeof the same type are equivalent to the certified engine.

This makes special demands on service and repairwork, as follows:

● Maintenance and service intervals recommendedby Volvo Penta must be complied with.

● Only Volvo Penta original spares may be used.

● Service to injection pumps, pump settings and injectors must always be done by an authorizedVolvo Penta workshop.

● The engine must not be converted or modified,except for the accessories and service kits whichVolvo Penta has approved for the engine.

● No installation changes to the exhaust pipe andengine air inlet ducts may be done.

● No seals may be broken by unauthorized personnel.

The general advice in the instruction book about oper-ation, care and maintenance applies.

IMPORTANT! Delayed or inferior care/mainte-nance, and the use of non-original spares partsmeans that Volvo Penta can no longer be re-sponsible for guaranteeing that the engine com-plies with the certified version.

Damage and/or costs which arise from this willnot be compensated by Volvo Penta.

Group 30: Electrical system General information


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Group 30: Electrical system Repair instructions

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Repair instructions

The working methods described in the workshop man-ual apply to work carried out in a workshop. For thisreason, the engine is lifted out and mounted on an en-

gine support. Unless otherwise stated reconditioningwork which can be carried out with the engine in placefollows the same working method.

The warning signs which occur in the workshop manual(please refer to “Safety information” for their meanings).

WARNING!

IMPORTANT!

NOTE!

are not comprehensive in any way, since we can not ofcourse foresee everything, because service work isdone in highly varying circumstances. For this reason,all we can do is to point out the risks which we believecould occur due to incorrect work in a well-equippedworkshop, using work methods and tools tested by us.

All operations described in the Workshop Manual forwhich there are Volvo Penta Special Tools availableassume that these tools are used when carrying outthe repair. Volvo Penta Special Tools have been de-

veloped to ensure the most safe and rational workingmethods possible. It is therefore the responsibility ofanyone using other tools or other working methodsthan we recommend to determine that there is no riskof personal injury or mechanical damage or malfunc-tion as a result.

In some cases special safety precautions and user in-structions may be required in order to use the tools andchemicals mentioned in the Workshop Manual. These

rules must always be observed, so there are no specialinstructions about this in the workshop manual.

By following these basic recommendations and usingcommon sense it is possible to avoid most of therisks involved in the work. A clean work place and aclean engine will eliminate many risks of personalinjury and engine malfunction.

Above all, when work on fuel systems, lubricationsystems, inlet systems, turbocharger, bearing capsand seals is done, it is extremely important that nodirt or other kinds of foreign particles are able to getin, since this would otherwise cause malfunctions orshortened repair life.


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Repair instructions Group 30: Electrical system

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Our common responsibilityEach engine consists of a large number of collaborat-ing systems and components. Any deviation of a com-ponent from its technical specification can dramatical-ly increase the environmental impact of an otherwisegood engine. For this reason, it is important that the

specified wear tolerances are observed, that systemswhich are adjustable are correctly adjusted and thatVolvo Penta Original Spares are used for the engine.The stated service intervals in the MaintenanceSchedule (see the Owner’s Manual) must be ob-served.

Some systems, such as the components in the fuelsystem, require special expertise and special testingequipment for service and maintenance. For environ-mental reasons etc., some components are sealed atthe factory. It is only permissible to work on sealedcomponents if you are authorized to do such work.

Remember that most chemical products, incorrectlyused, damage the environment. Volvo Penta recom-mends the use of biodegradable degreasers wheneverengine components are de-greased, unless otherwisespecified in the workshop manual. When workingaboard a boat, be careful to ensure that oils, washresidue etc. are processed for destruction, and are notinadvertently discharged with bilge water into the envi-ronment.

Tightening torquesThe tightening torque for vital fasteners, which shouldbe tightened with a torque wrench, are listed in “Tech-nical Data: Special tightening torques” and noted in the job descriptions in the book. All torque specificationsapply to clean screws, screw heads and mating faces.

Torque data stated apply to lightly oiled or dry threads.If lubricants, locking fluids or sealants are needed on afastener, the type of preparation to be used will be not-ed in the job description and in “Tightening Torques”.For fasteners where specific torque values are not giv-en, please refer to “Technical data: General tighteningtorques”. General torque specifications are target val-ues and the fastener does not need to be tightened witha torque wrench.

Dimension TorqueNm

M5 ................................................. 6

M6 ................................................. 10

M8 ................................................. 25

M10 ............................................... 50

M12 ............................................... 80

M14 ............................................... 140

M16 ............................................... 220


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Special tools

3838619 VODIA complete diagnostic tool.*Components:

3838620 VODIA – palmtop computer (PDA) with SD card.

3838621 VODIA – docking station. Used with VODIA PDA(3838620).

3838622 VODIA – cable with connector. Used with dock-ing station (3838621) on the engine’s communi-cation connector.

*Note. More detailed information about using the VODIA tool canbe 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

8856753838619

3838620 3838621 3838622

9812519

Special tools Group 30: Electrical system

888900169998699

9999324 9998482


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EMS 2 - “Engine Management System” Group 30: Electrical system

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EMS 2 - “Engine Management System”

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

The system consists of a control module, six injectors, a number of sensors that supply the control module withmeasurements, sockets for diagnosis and functional checks. The engine can be connected to a communicationsinterface consisting of a CAN link and a serial link.

CAN - Controller Area Network The J1939 CAN link is responsible after all communi-cation between the engine control unit (EMS 2) and acommunication interface (such as CIU/DCU), exceptfor diagnostics. Diagnostics are managed by the so-called J1708/J1587 link. The CAN link is much fasterthan the J1708/J1587 link and has been designed to

connect to other components that support the SAEJ1939 protocol, such as instrument panels and trans-missions.

If a fault develops on the CAN link, signals for the en-gine speed potentiometer, and the start and stopknobs are taken over by the J1708/J1587 link. Howev-er, instrument and indicator lamps are completelyturned off.

If faults occur in both links, the engine starts to idle.The only way to shut off the engine in this case is touse the auxiliary stop (AUX-STOP).


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Group 30: Electrical system EMS 2 - “Engine Management System”

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DCU - Display Control UnitDCU is a digital instrument panel that communicateswith the engine control module via the CAN link. DCUhas several functions, such as:

Engine control

– Start, stop, speed control, preheating etc.

Monitoring– Engine speed, boost pressure, boost temperature,

coolant temperature, oil pressure, oil temperature,engine hours, battery voltage, instantaneous fuelconsumption and fuel consumption (trip fuel).

Diagnostics

– Shows fault codes in text. Lists previous faults.

Parameter setting

– Idling speed, alarm limit for oil temperature/cool-ant temperature, droop.

– Preheating for ignition.Information

– Information about hardware, software and engineidentification.

CIU - Control Interface UnitThe CIU is a “translator” between the CAN bus andthe customer’s own control panel. This unit has twoserial communication links, one fast and one slow.

The fast one is a CAN link that features a bus speedof 250 Kbit/s. All data regarding instruments, indicator

lamps, contacts and potentiometers are controlled bythis bus.

The slower J1708/J1587 link handles diagnostic infor-mation for, among other things, the flashing code. TheVODIA diagnosis tool also uses the J1708/J1587 linkto communicate with the system.


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EMS 2 - “Engine Management System” Group 30: Electrical system

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Fuel controlThe amount of fuel injected into the engine and the injection advance are fully electronically controlled, viafuel valves in the injectors, once the control unit hasanalyzed the engine’s fuel requirements.

This means that the engine always receives the cor-

rect volume of fuel in all operating conditions, whichoffers lower fuel consumption, minimal exhaust emis-sions etc.

The control unit monitors and reads the injectors toensure that the correct volume of fuel is injected intoeach cylinder, and it calculates and set the injectionadvance. Control is mainly done with the help of thespeed sensors, fuel pressure sensor and the com-bined sensor for boost pressure/boost temperature.

The control unit controls the injectors via a signal tothe electromagnetically operated fuel valve in each injector, which can be opened and closed.

Calculation of fuel quantityThe quantity of fuel to be injected into the cylinder iscalculated by the control unit. The calculation deter-mines the time that the fuel valve is open (when thefuel valve is open fuel is sprayed into the cylinder).The parameters which govern the amount of fuel injected are:

• Demanded engine speed

• Engine protector functions• Temperature

• Boost pressure

Altitude correctionThe control unit contains an atmospheric pressuresensor and an altitude compensation function for en-gines that operate at high altitude. This function limitsthe fuel volume in relation to ambient air pressure.This is to prevent smoke, high exhaust temperatureand to protect the turbocharger from overspeeding.

Diagnostic functionThe task of the diagnostic function is to discover andlocalize any malfunctions in the EMS 2 system, toprotect the engine and to inform about any problemsthat occur.

If a malfunction is discovered, this is announced bywarning lamps, a flashing diagnostic lamp or in plain lan-guage on the instrument panel, depending on the equip-

ment used. If a fault code is obtained as a flashing codeor in plain language, this is used for guidance in any faulttracing. Fault codes can also be read by Volvo’s VODIAtool at authorized Volvo Penta workshops.

In case of serious disturbances, the engine is shutdown completely or the control module decreases thepower output (depending on the application). Onceagain, a fault code is set for guidance in any faulttracing.


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Group 30: Electrical system Component location

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Component location TAD 650, 660, 750, 760 VE

NOTE! Location can differ, depending on engine model.

1. Speed sensor, camshaft

2. Connection, 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 primaryfuel filter).

1

2

34 5

6

7

8

9

10

11


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Component description Group 30: Electrical system

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Component location TAD 734 GE

1. Solenoid controlled proportional valve,high pressure pump – fuel (MPROP)

2. Coolant temperature sensor

3. Water in fuel switch(mounted on primaryfuel 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


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Group 30: Electrical system Component description

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Starter motorThe starter motor is installed in the flywheel housing,on the left-hand side of the engine. The starter motorrelay is “positive connected”, which means that the re-

lay is connected to battery voltage.

AlternatorThe alternator is belt driven and mounted on the frontof the engine, on the right.

Component description


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InjectorsThe injectors are installed on the cylinder head.

The amount of fuel injected and injection duration iscontrolled by the engine control unit, via electromag-netically controlled fuel valves in the injectors. Thismeans that the engine always receives the correct

volume of fuel in all operating conditions, which offerslower fuel consumption, minimal exhaust emissionsetc.

Speed sensor, crankshaftThe engine speed sensor is an inductive sensor.When the crankshaft rotates impulses are created inthe sensor via a tooth wheel on or behind the torsiondamper. The impulses create a pulse signal in thesensor that the engine control unit (EMS 2) uses tocalculate 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, whichcalculates the injection in advance and the amount offuel to be injected.

Speed sensor, camshaft (cam-shaft position)The camshaft sensor is an inductive sensor. Whenthe camshaft rotates impulses are created in the sen-sor via a tooth wheel installed on the camshaft. Thetooth has seven teeth, one for each cylinder and oneto determine when cylinder one is to be injected. Theimpulses create a pulse signal in the sensor that theengine control unit (EMS 2) uses to calculate when acylinder is in turn for injection.


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Sensor, boost pressure/ boosttemperatureThe boost pressure and the boost temperature aremeasured by a combined sensor located on the inletmanifold on the left of the engine.

The sensor is supplied by a 5 Volt reference voltage

from the engine control module.

The boost pressure sensor measures the absolutepressure, which is the sum of the boost pressure andatmospheric pressure (300 kPa thus corresponds to aboost pressure of 200 kPa when atmospheric pres-sure is 100 kPa).

The pressure signal is a voltage signal which is pro-portional to absolute pressure.

The 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, engineOil pressure is measured by a sensor installed in theengine block on the right side of the engine.

The sensor measures pressure in the main oil gallery,and is supplied by a 5 Volt reference voltage from theengine control module.

The pressure signal is a voltage signal which is pro-portional to the lubrication oil pressure.

IEGR (only VE engines)The IEGR valve is a 2-way solenoid valve controlled bythe engine control unit. The IEGR solenoid controls aoil pressure that effects a control valve which activatethe exhaust gas recirculation function.


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Sensor, fuel pressureThe sensor measures fuel pressure and is located on

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

Coolant temperature sensorThe sensor is located on the cylinder head, at the rearend of the engine.

The sensor senses the engine coolant temperatureand 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, atthe front of the common rail, which distributes fuel tothe injectors.

The rail pressure sensor senses the fuel pressure andconverts this to a voltage which is registered by theengine control unit.


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Magnetically controlled propor-tional valve (MPROP)

A magnetically controlled proportional valve (MPROP)controls the high pressure pump to ensure that thecorrect fuel pressure (rail pressure) is retained despitevarying engine speed and loading.

The input signal to the valve is a PWM signal whosepulse width is controlled by the engine control module.

When the current through the valve is changed, this af-fects the fuel flow, which results in changed rail pres-sure.

Water in fuel switch, secondaryfuel filterA switch is located in the water trap under the fuel fil-ter. Its task is to detect whether there is water in thefuel.

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 isany water in the fuel, the resistance falls.

Switch, coolant level

The task of the switch is to discover whether the cool-ant level in the engine (expansion tank) has becometoo low. An alarm signal is sent when the coolant levelis too low.


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Engine control unit, EMS 2The engine control unit checks and controls the injec-tors, to ensure that the correct volume of fuel is inject-ed into each cylinder at the right time. It also controlsthe high pressure pump via the proportional valve(MPROP) to ensure that the system always has thecorrect fuel pressure (rail pressure).

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 forboost pressure/boost temperature.

The EMS 2 system processor is located in the controlunit, 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 information about current op-eration conditions and allows the processor to calculatethe correct fuel volume, monitor engine status etc.

Preheater with preheater relay

The preheater is located in the inlet manifold at the leftside of the engine. The preheat relay is located at theengines left side beneath the preheater.


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19

General advice on workingwith EMS engines

The following advice must be followed to avoiddamage to the engine control unit and other elec-tronics.

IMPORTANT! The system must be disconnect-ed from system voltage (by cutting the currentwith the main switch) and the starter key(s) mustbe in the 0 position when the engine controlmodule connectors are disconnected or connect-ed.

● Never disconnect the current with the mainswitches when an engine is running.

● Never undo a battery cable when the engine isrunning.

● Turn the main switches off or disconnect the bat-tery cables during quick charging of the batteries.

● NOTE! During normal trickle charging, it is notnecessary to turn the main switches off.

● Only batteries may be used for start help. A help

start device can produce a very high voltage anddamage the control unit and other electronics.

● If a connector is disconnected from a sensor, bevery careful to avoid allowing the contact pins tocome into contact with oil, water or dirt.

Repair instructions


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20

Electric welding

1. NOTE! Cut the current with the main switch.

IMPORTANT! The system must be disconnect-ed from system voltage when the engine controlmodule connectors are disconnected or con-

nected.

2. Undo the two connectors from the engine controlunit before any electric welding starts. Turn thelocking 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 componentto be welded, or as close as possible to the weldsite. The clamp must never be connected to the

engine or in such a way that current can passthrough a bearing.

IMPORTANT! After welding is completed, thedisconnected components, such as alternatorcables and battery cables must be connected inthe correct order.The battery cables must always be connectedlast.


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21

Changing the engine controlunit


IMPORTANT! The system must be disconnect-ed from system 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 sametime as the connector is pulled outwards

3. If the new engine control unit has recently beenprogrammed:

Start the engine and check whether any fault

codes related to the engine control unit occur.


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Reprogramming a control unit

IMPORTANT! The CHASSIS ID number mustbe readily available to allow the software to bedownloaded.

Action:

1. Log in to Volvo Penta Partner Network’s web-site:

www.vppn.com

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

3. Choose “ECU programming” in the left-handmenu.

4. Follow the instructions under “Download soft-

ware”. Choose the control units to be repro-grammed and click the “Download” button. Thesoftware for the control units is now downloadedto the PDA*.

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

5. Take a look under “Settings”, “Software informa-tion” in VODIA to check that the software hasbeen 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” inthe 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 instruments” in theVODIA menu.

Select “MID 144 ECU, programming”.

VODIA will guide you through the entire program-ming process.

9. NOTE! Programming must be reported back toVolvo Penta within 28 days. Log in to Volvo Pen-ta Partner Network’s web site:

www.vppn.com


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

12. Follow the instructions for “Report software/pa-rameter”. Click “Report software/parameter”.


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23

Programming an emptycontrol unit

When a new engine control unit is installed, where nosoftware has been downloaded, the control unit mustbe programmed.

The new control unit must have the same part numberas the old control unit. If the control units do not havethe same part number, it will not be possible to pro-gram the new control unit until a “Conversion kit” hasbeen ordered from Volvo Penta.

If the control units have the same part number, thenew control unit can be programmed as usual. Pleaserefer 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


4. Choose “Conversion kit” in the left-hand menu. Anew page, “Conversion kit / Accessory kit”, opensup.

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

6. A new window opens. Follow the instructions giv-en in the window.

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

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

9. Programing of the control unit can now start.Please refer to “Programming a control unit”.


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24

Fault tracing of cables andconnectors

Special tools: 9812519, 9998482

Check all connectors visually

Check the following: Look for oxidation which can impair contact in con-

nectors.

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

● Check that there is good mechanical contact in theconnector. Use a loose pin to check this.

IMPORTANT! The multi-pin connectors forthe engine control unit must only be checkedwith gauge 9998482.

● Carefully insert gauge 999 8482 into the multi-pinconnector. Pull and push the connector in and outa few times and feel whether the terminal socketgrasps the tool. If the terminal socket does notgrasp, or if it feels slack, the connection pinsshould be changed. Please refer to ”Joining electri-cal cables for multi-connector” Check the second-ary locking in the connector.

● If possible, shake the cables and pull the connec-

tors during measurement to discover whether thecable harness is damaged.

● Check that the cables are not damaged. Avoidclamping cables in tight bends close to the con-nector.

● Check the function of the secondary locking.

Contact problems

Intermittent contact or temporary recurring faults canbe difficult to fault trace, and are frequently caused byoxidation, 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 topins, sockets and connectors etc.

Shake cables and pull connectors during measure-ment, to find where the cable is damaged.

Contact resistance and oxidation

Resistance in connectors, cables and junctionsshould be close to 0 Ω. A certain amount of resistancewill occur, however, because of oxidation in connec-tors.

If this resistance is too great, malfunctions occur. Theamount of resistance that can be tolerated before mal-functions occur varies, depending on the load in thecircuit.

Open circuit

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

Use the wiring schedule to check the cable harnesses

which are relevant to the function. Start off with themost probable cable harness in the circuit.

Check the following:

● Disconnect the relevant connector at each end ofthe cable harness.

● Use multimeter 9812519 to measure the resis-tance between the ends of the cable.Nominal value close to 0 Ω.

● If possible, shake the cables and pull the connec-tors during measurement to discover whether thecable harness is damaged.

● Check the next cable harness in the wiring sched-ule if no fault has been found.


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25

Joining electrical cables forconnectors

Special tools: 9808648, 9999324

Repair kit: 1078054

1Disconnect the connector from the engine control unitor from the power supply unit, please refer to ”Controlunit, changing”.

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

2Undo 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 kit10.78054. Use cable crimping tool no. 9999324.

5Carefully heat the joint with a hot air gun, to make the

insulation shrink and seal tightly.


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26

Checking the starter motor

voltageSpecial tools: Multimeter 9812519

General

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

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

* Note. Measured on the batteries.

Voltage measurement, check

1Check that the battery voltage is at least 24.7 V* whenunloaded by using multimeter 981 2519 to measurebetween the battery poles.

* Note. Measured on the batteries.

2Turn the main switch on.

3Check that the voltage between terminal B+ on the start-er motor and battery negatives connection point is thesame as the battery voltage.

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

7

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

8Install the connector in the reverse order to disassembly.

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

10Join up the multi-pin connector. Please refer to ”Con-trol unit, changing” for advice on joining up the connec-tor.

11Start the engine and check carefully that no faultcodes occur.


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27

Checking the charging system

Special tools: 9812519

Generally about alternators:

The voltage output from an alternator must be limitedto prevent the elecrolyte in the battery to evaporate.The alternator output is regulated (limited) by the volt-age regulator in the alternator. The maximum currentthat the alternator can deliver at regulated voltage out-put depends on the alternator revolution. When the en-gine is started an excitation current is needed to“wake up” the alternator.

NOTE! It is the consumers (batteries included) whichdecides the output current from the alternator.

Measurements

1. Engine off.

2. Use multimeter 9812519 to do a voltage measure-ment over the battery. The nominal voltage over afull loaded battery is approx. 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 correctassembled.

2. Check the conditions of the cables to the battery.

3. Check the water level in the battery.

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

when no charge

1. Check the alternator belt tension.

2. Check that all connectors at the alternator and atthe battery is correct assembled.

3. Check the conditions of all cables in the chargingsystem.

4. Regulator fault, try another alternator.

when undercharge1. Check the alternator belt tension.

2. Check that all connectors at the alternator and atthe battery is correct assembled.

3. Check the conditions of all cables in the chargingsystem.

4. Regulator fault, try another alternator.

when overcharge

1. Probably regulator fault, try another alternator.


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Rail pressure measurement

This measurement is used for measuring the rail pres-sure. For example if the engine doesn’t start this mea-surement can show the rail pressure while the engineis cranking. If it is air in the system the rail pressure

could be too low for the engine control unit to activateinjection.

1. NOTE! Starter key in position 0.

2. Undo the connector from the sensor.

3. Connect adapter cable (885675) between the sen-sor and the engine control unit.

4. Use multimeter (9812519) for voltage measure-ment. Connect the COM from the multimeter tomeasurement point 1. Connect V from the multim-eter to measurement point 2.

5. NOTE! Starter key in position I. The multimetershould now show 0.5 Volt which is equal to 0Mpa(0bar).

6. When cranking the engine, read the voltage valueon the multimeter and look in the table which pres-sure the voltage equals.

NOTE! To activate injection a rail pressure of at least25 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 0 203.0 225.0 270.0 315.0 360.0 405.0 450.0 495.0 540.0

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 99.0Bar 585.0 630.0 675.0 720.0 765.0 810.0 855.0 900.0 945.0 990.0

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 1035.0 1080.0 1125.0 1170.0 1215.0 1260.0 1305.0 1350.0 1395.0 1440.0

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 1485.0 1530.0 1575.0 1620.0 1665.0 1710.0 1755.0 1800.0


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Group 30: Electrical system Malfunctions

29

Malfunctions

Fault code information

MID - Message Identification Description:The MID consists of a number which designatesthe control unit that sent the fault code message.(e.g. the engine control unit).

• PID - Parameter Identification Description:The PID consists of a number that designates aparameter (value) to which the fault code relates(oil pressure, for example).

• PPID - Proprietary PID:The same as the PID, but this is a Volvo-specificparameter.

• SID - Subsystem Identification Description:The SID consists of a number that designates acomponent to which the fault code relates(injector, for example).

• PSID - Proprietary SID:The same as the SID, but this is a Volvo-specificcomponent.

• FMI - Failure Mode Identifier:FMI indicates the type of fault (please refer to theFMI table below).

• SPN - Suspect Parameter Number


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Malfunctions Group 30: Electrical system

30

FMI table

SAE standard

FMI Display text SAE text

0 “Value too high” Valid data, but above the normal working range

1 “Value too low” Valid data, but below the normal working range2 “Faulty data” Intermittent or faulty data

3 “Electrical fault” Abnormally high voltage or short circuit to higher voltage

4 “Electrical fault” Abnormally low voltage or short circuit to lower voltage

5 “Electrical fault” Abnormally low current or open circuit

6 “Electrical fault” Abnormally high current or short circuit to battery negative

7 “Mechanical fault” Faulty response from mechanical system

8 “Mechanical or electrical fault” Abnormal frequency

9 “Communication fault” Abnormal updating rate

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 normal operating range - least severe level

18 Data valid but above normal operating range - moderately severe level19 Received network data in error

20 Reserved for SAE assignment











31 Condition exist


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Volvo-specific for injectors

(MID 128, SID 1–6)

FMI Help

3 Short circuit to battery voltage, injector low voltage side

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

5 Open circuit in injector circuit

7 Mechanical system not responding properly

12 Low injector hold current

General advice

NOTE!

The following must be done before fault trac-ing continues, to avoid changing functionalsensors:

● If there is an active/inactive fault code.

Remove the connector from the sensor. Checkthat there is no oxidation and that the connectorpins are not damaged.

If there is a fault, please refer to the instructionsin chapter “Fault tracing of cables and connec-tors”.

NOTE! Some fault codes become inactive when theengine is stopped. Start the engine to check whetherthe fault code is still inactive with the engine running.

● After an action with the connector

Put the connector* back. Check if the fault codebecomes inactive.

Check faults that could be related to that specif-ic sensor.

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

*NOTE! No grease in the connector.


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Malfunctions Group 30: Electrical system

32

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 stan-dard for distributed systems.

The CAN bus consists of a pair of copper conductorswhich 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 benefitsfrom each other’s services.

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

J1587

The communication bus, J1587, is also used for ac-cessories and for diagnostics.

This is a serial bus in accordance with standard SAEJ1708.


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Manual fault tracing in buscables

Special tools:Multimeter ..................................................... 9812519

IMPORTANT! Cut the current with the mainswitch before the cables are disconnected.

Use the multimeter to check the bus cables. The con-ductors in the bus cables should not be in contactwith each other.

Disconnect a bus cable at each end and measure theresistance between the pins to check this. The multi-meter should show infinite resistance between eachpin. If the resistance is less than infinite, there is afault.

Measuring the engine cablesTwo types of measurement are done on the enginecable harness, both resistance measurement and volt-age measurement.

The measurements are done to ensure that no opencircuits 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. Theresistance values given in the workshop manual areapproximate, and should be regarded as guidelines.

NOTE!

When resistance measurement is done, the engineshould be stopped and system voltage should becut off with the main switch.

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


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Diagnostic Trouble Codes Group 30: Electrical system

34

MID 128, PID 45

Inlet air heater status

MID 128: Engine control unit

FMI 3: The voltage exceeds the normal value or isshort circuited to higher voltage.

FMI 4: The voltage is less than the normal value oris short circuited to lower voltage.

FMI 5: The current is less than the normal value oris 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. Whitesmoke for cold start. Start problems in

cold climate.FMI 4: Induction air is hot. Preheat relay is im-

possible to turn off. Preheat fuse willbreak.

Diagnostic Trouble Codes


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Group 30: Electrical system Diagnostic Trouble Codes

35

Circuit description

In cold climate the intake air need too be preheated.This is either done for GE engines by the preheaterwhich is located in the inlet manifoldor or for VE en-gines by the glowplugs that are mounted in the cylin-derhead. The preheat function is activated/deactivated

by the engine control unit via the preheat relay. Whenthe preheat function is activated B25 alter its potentialand the relay activates. B7 is a sense cable whichsenses 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 EMS2 and preheat relay.

Suitable action:

1. Check cable harness and connectors betweenEMS 2 and preheat relay.

pre-heat relay

FMI 4 Abnormally low voltage or short

circuit to lower voltage

Possible reason:

• Short circuit to battery negative in cable harnessbetween EMS 2 and preheat relay.

Suitable action:



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FMI 5 Abnormally low current or open

circuit

Possible reason:

• An open circuit in cable harness between EMS 2and preheat relay.

Suitable action:

1. Check the contact pressure in socket 25 in theengine connector B.


Measurements

NOTE! If any of the measurements shows an abnor-mal value, check the wiring to and from the enginecontrol unit and the preheat relay.

Checking the wiring:


2. Remove connector B from the EMS 2.

3. Connect the B connector to brakeout cable9990014 with measurebox 9998699.

4. Use multimeter 9812519 to do a resistance mea-surement.

Measurement points on box Nominal value 7 (preheat sense) - R ≈ 0 Ω one of the preheat connectors

25 (relay activation) - R ≈ 0 Ω one of the preheat connectors

60 (relay +) - R ≈ 0 Ω one of the preheat connectors


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Circuit description

The sensor is an active sensor, i.e. the sensor mustreceive operating voltage. Pin B17 on the engine con-trol unit provides pin 1 on the sensor with an operatingvoltage of +5 Volt. Pin 4 on the sensor is connected tobattery negative via pin B18 on the engine control unit.The output signal from the pressure sensor, pin 2 onthe sensor to pin B16 on the EMS 2, is a voltage sig-nal that is proportional to the fuel pressure.

MID 128, PID 94

Fuel pressure


FMI 1: The sensor value is valid but below the nor-mal working range.



FMI 7: Mechanical fault. The system responds in-correctly.


1 Fuel pressure is too low

3, 5 Faulty sensor / Faulty sensor circuit

7 Fuel pressure is critically low

Fault indication


CIU: Flash code

Flash code


Value fault: 3.8

Symptom

None

splice

splice fuel pres-

sure

engine

interface

Note! Only TAD 650, 660, 750, 760 has an engine interface. On

TAD 734 the wiring to the EMS 2 is the same but without any en-gine interface.


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Fault tracing

FMI 1 Fuel pressure is too low

Conditions for fault code:

The fuel pressure alarm depends on the engine revo-

lution.Suitable action:

1. Check fuel level.

2. Open all fuel cocks and check that no leakageoccurs.

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 controlmeasuring the fuel pressure. (see workshop man-

ual)7. Check fuel feed pump.

8. Change fuel pressure release valve. (see work-shop manual)




The voltage on pin B16 on the EMS 2 is more than4,75 Volt.

Possible reason:

• An open circuit in fuel sensor negative cable.

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

• Faulty sensor.

Suitable action:

1. Check contact pressure in socket 18 in the engineconnector B. Also check contact pressure in con-nector at fuel pressure sensor.

2. Check cable harness and connectors between fuelsensor and EMS 2.

3. Check function of fuel pressure sensor.


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circuit


The voltage on pin B16 on the EMS 2 is less than0.07 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 neg-ative.

• Faulty sensor.

Suitable action:

1. Check contact pressure in socket 16 and 17 inthe engine connector B. Also check contact pres-

sure in connector at fuel pressure sensor.

2. Check cable harness and connectors between fuelsensor and EMS 2.

3. Check function of fuel pressure sensor.

FMI 7 Critically low pressure


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. 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 controlmeasuring the fuel pressure. (see workshop man-ual)

7. Check fuel feed pump.

8. Change fuel pressure release valve. (see workshopmanual)


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40

Measurements

NOTE! If any of the measurements shows an abnor-mal value, check the wiring to and from the engine in-terface.

Supply cable• NOTE! Turn ignition off.

• Disconnect the connector from the sensor

• Connect adapter cable 885675 to the cable har-ness connector to the 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.



• Use multimeter 9812519 to do resistance mea-surement against the engine control unit.


4 – Battery negative R ≈ 0 Ω

The point of connec-

tion for battery nega-tive on the engine


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41

Signal cable:




• Use multimeter 9812519 to do resistance mea-

surement against the engine control unit.


4 – 2 R ≈ 80 - 120 kΩ

NOTE! Measurement is done to eliminate short cir-cuiting or breaks in the cable to the engine controlunit.


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Checking fuel pressure sensor

• NOTE! Turn ignition off.


• Connect adapter cable 885675 between the sen-sor and the engine control unit.




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 voltage5,00 VDC:

0,5 VDC at 0 bar = 0 kPa


O u t p u

t v o l t a g e , V

Fuel pressure, kPa


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43

splice

water in

fuel

MID 128, PID 97

Water in fuel


FMI 0: The sensor value is valid but above the nor-mal working range.




0 Water in fuel

3, 4 Faulty sensor / Faulty monitor circuit

Fault indication

DCU: Engine warning in DCU display

CIU: Flash code

Flash code


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 thefuel.

The monitor 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 isany water in the fuel, the resistance falls.

At a threshold resistance (water has been detected),the monitor’s output signal (yellow cable) to the enginecontrol unit pin B8 will be pulled down to zero.


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Fault tracing

FMI 0 Water in fuel


Water in the fuel trap has been detected.

Suitable action:

1. Empty the water trap.

2. Check function of water in fuel monitor.

FMI 3


The voltage signal on B8 is too high.

Possible reason:

• The cable connected to B8 is short circuited tobattery voltage.

Suitable action:

1. Check cable harness and connectors between wa-ter in fuel monitor and EMS 2.

FMI 4


The voltage signal on B8 is too low.

Possible reason:

• Short circuit between both cables to the water infuel monitor.

• The cable connected to B8 is short circuited tobattery negative.

Suitable action:

1. Check cable harness and connectors between wa-ter in fuel monitor and EMS 2.


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Measurements

Supply cable:


• Disconnect the connector from the monitor

• Use multimeter 9812519 for voltage measurement

• NOTE! Turn ignition on.


Yellow conductor – U ≈ Battery voltage x 0.8Black conductor

Negative cable:


• Disconnect the connector from the monitor



Black conductor – R ≈ 0 ΩBattery 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 the monitor.


1 – 2 Monitor immersed R ≈ 0 Ωin water

1 – 2 Monitor immersed R ≈ ∞ Ω

in fuel


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46

MID 128, PID 100

Oil pressure


FMI 1: The sensor value is valid but below the nor-mal working range.




1 Oil pressure is too low


Fault indication


CIU: Flash code

Flash codeElectrical fault: 3.1

Value fault: 6.6

Symptom

FMI 1: Power is reduced due to error torque map ifengine protection parameter is activated.


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47

Circuit description

The sensor is an active sensor, i.e. the sensor mustreceive operating voltage. Pin B17 on the engine con-trol unit (EMS 2) provides pin 1 on the sensor with anoperating voltage of +5 Volt. Pin 3 on the sensor isconnected to battery negative via pin B18 on the EMS

2.The output signal from the pressure sensor, pin 2 onthe sensor to pin B11 on the EMS 2, is a voltage sig-nal that is proportional to the oil pressure (after the oilfilters).

Fault tracing

FMI 1 Oil pressure is too low


Oil pressure depends on the engine revolution. Oilpressure 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 blockedoil filter.

3. Check that no engine oil leakage occurs.

4. Check function of oil pressure sensor by controlmeasuring the engine oil pressure (see workshopmanual Group 21-26).

oil pressuresplice

splice

Note! Only TAD 650, 660, 750, 760 has an engine interface. OnTAD 734 the wiring to the EMS 2 is the same but without any en-gine interface.


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48




The voltage on pin B11 on the EMS 2 is more than4.95 Volt.

Possible reason:

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

• Faulty sensor.

Suitable action:

1. Check cable harness and connectors between oilpressure sensor and EMS 2.

2. Check function of oil pressure sensor.


circuit


The voltage on pin B11 on the EMS 2 is less than 0.07Volt.

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 batterynegative to oil pressure sensor.

• Faulty sensor.

Suitable action:

1. Check contact pressure in socket 11 and 17 inengine connector B. Also check contact pressurein connector at oil pressure sensor.

2. Check cable harness and connectors between oilpressure sensor and EMS 2.

3. Check function of oil pressure sensor.


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49

MeasurementsNOTE! If any of the measurements shows an abnor-mal value, check the wiring to and from the engine in-terface.

Supply cable:

• NOTE! Turn ignition off.• Remove the connector from the sensor.

• Connect adapter cable 885675 between the sen-sor and engine control unit.


• NOTE! Turn ignition on.


1 – 3 U ≈ 5 V

Negative cable:







The point of con-

nection for batterynegative on the en-

gine


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50

Signal cable:







2 – 3 R ≈ 80 -120 kΩ

NOTE! Measurement is done to eliminate short cir-cuiting or breaks in the cable to the engine controlunit.


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51

Component specificationWorking range: 0 – 7 bar = 0 – 700 kPa

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

Nominal output voltage at 25 °C and at supply voltage5,00 VDC:



Checking the oil pressure sensor



• Connect adapter cable 885675 between the sen-sor and the engine control unit.




2 – 3 U ≈ 0,5 V (at normalatmospheric pres-sure)

O

u t p u t v o l t a g e , V

Oil pressure, kPa


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52

MID 128, PID 105

Boost temperature






0 Boost temperature is too high


Fault indication


CIU: Flash code

Flash code


Value fault: 6.2

Symptom

FMI 0: Engine is derated if engine protection pa-rameter is activated.

FMI 4, 5: Pressure set to 40° C.


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53

Circuit description

The boost temperature sensor consists of a thermistorwhich forms a closed circuit with an internal resistor inthe engine control unit (EMS 2), via the engine inter-face. The thermistor resistor changes in a non-linearmanner, depending on the boost temperature.

The EMS 2 provides the circuit with a reference volt-age of +5 Volt. The EMS 2 measures the voltage dropover the thermistor via pin A47 and pin A11 on theEMS 2. Pin 1 on the sensor is connected to batterynegative via pin A11 on the EMS 2.

When the boost air is cold, the thermistor resistanceis high and the EMS 2 senses a high voltage drop. Asthe 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


Boost temperature exceeds the set value of the en-gine protection parameter.

Possible reason:

• Engine temperature is too high.

• High surrounding temperature.

• Dust or dirt on the outside of the intercooler.

• Faulty boost temperature sensor.

Suitable action:1. Check that engine temperature is normal.

2. Clean the intercooler.

3. Check function of boost temperature sensor.

splice

Boost air andtemperaturesplice

engineinterface



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54

FMI 4 Abnormally low voltage or short

circuit to lower voltage


The voltage on pin B47 on the EMS 2 is less than 0.07Volt.

Possible reason:

• Short circuited sensor signal cable to battery neg-ative.

• Faulty sensor.

Suitable action:

1. Check cable harness and connectors betweenboost temperature sensor and EMS 2.



circuit


The voltage on pin B47 on the EMS 2 is more than4.95 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 voltageor to battery voltage.

• Faulty sensor.

Suitable action:

1. Check contact pressure in socket 47 and 7 in en-gine connector A. Also check contact pressure inconnector at boost temperture sensor.

2. Check cable harness and connectors betweenboost temperature sensor and EMS 2.



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55

MeasurementsNOTE! If any of the measurements shows an abnor-mal value, check the wiring to and from the engine in-terface.

Signal cable:







1 – 2 U ≈ 5 V

Negative cable:








The point of con-

nection for bat-

tery negative onthe engine


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Checking the sensor cable for open circuit orshort-circuit:


• Disconnect the connector from the sensor.

• Connect adapter cable 885675 to the cable har-

ness 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.


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 breaks in the cable to the engine control unit.


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Checking boost temperaturesensor


• Connect adapter cable (885675) to the sensor. Donot connect the other end of the adapter cable.

• Use multimeter 9812519 to do resistance mea-surement.


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 )


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MID 128, PID 106

Boost pressure






0 Boost pressure is too high


Fault indication


CIU: Flash code

Flash code


Value fault: 3.5

Symptom

FMI 0: Power is reduced due to error torque mapif engine protection parameter is activat-ed.

FMI 3, 5: Pressure set to atmospheric pressure+ 30 kPa. Engine performance is derated.


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59

Circuit description

The sensor is an active sensor, i.e. the sensor mustreceive operating voltage. The boost pressure sensormeasures the absolute pressure, which is the sum ofthe boost pressure and atmospheric pressure (300kPa thus corresponds to a boost pressure of 200 kPa

when atmospheric pressure is 100 kPa).Pin A7 on the engine control unit (EMS 2) provides pin3 on the sensor with an operating voltage of +5 Volt.Pin 1 on the sensor is connected to battery negativevia pin A11 on the EMS 2. The output signal from thepressure sensor, pin 4 on the sensor to pin A22 on theEMS 2, is a voltage signal that is proportional to theboost pressure.

Fault tracing

FMI 0 Boost pressure is too high


Boost pressure exceeds the set value of the engineprotection 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 functionality (see workshopmanual Group 21-26).

2. Check function of boost pressure sensor by con-trol measuring boost pressure using a measuringtap (see workshop manual Group 21-26).

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

splice

boost air and

temperaturesplice

engine

interface



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60


workshop manual gp.30 volvo penta tad760ve .pdf

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