Professional Documents
Culture Documents
VOLVO
Engine
TAD734GE
7747622 - 7747632
33525076901_1_1
05-2008
Workshop Manual I
Group 00-08, 20-26, 32-37 4(0)
TAD734GE
Content
General Information
00-0 General ................................................................................................. 2
Specifications
03-2 Specifications, Engine ........................................................................ 6
Special Tools
08-1 Universal Tools .................................................................................. 20
08-2 Special Service Tools ....................................................................... 22
General
20-0 Engine Information, General............................................................. 25
Engine
21-0 Engine Complete, General ............................................................... 61
21-1 Cylinder Head ................................................................................... 112
21-4 Valve Mechanism ............................................................................ 133
21-6 Crank Mechanism ............................................................................ 137
Fuel System
23-0 Fuel System, General ...................................................................... 168
23-3 Fuel Feed Pump and Filter ............................................................. 170
23-7 Injectors and Delivery Pipes .......................................................... 181
23-8 Control System ... ........................................................................... 193
Cooling System
26-1 Radiator, Heat Exchanger ............................................................... 213
26-2 Coolant Pump, Thermostat ............................................................. 221
Starting System
33-1 Starter Motor .................................................................................... 238
2 7747622 05-2008
00-0 General
7747622 05-2008 3
00-0 General
Example: For 90 angle tightening, the fastener is In each service manual section concerned, the seal-
turned a further 1/4 turn in one sequence, after the ants used in product manufacture are indicated. The
specified tightening torque has been achieved. same sealants, or sealants with equivalent proper-
ties, must be used for maintenance work.
Lock nuts
Make sure that mating surfaces are dry and free from
Removed locknuts may not be re-used; they must be oil, grease, paint and anti-corrosion agent before
replaced by new ones, as locking properties are applying sealant or locking fluid. Always follow the
impaired or lost with re-use. manufacturer's instructions regarding applicable
In the case of lock nuts with plastic inserts the tight- temperatures, hardening times and such.
ening torque indicated must be reduced if the nut has
the same nut height as a standard, all-metal hexag- Two basic types of compound are used:
onal nut.
RTV preparations (Room Temperature Vulcaniz-
Reduce the torque by 25% for bolt sizes of 8 mm or
ing).
larger.
Used most often together with gaskets, e.g. sealing
In the case of lock nuts with plastic inserts with a high
gasket joints, or are brushed on gaskets. RTV seal-
nut-height (where the all-metal thread is as high as a
ants are completely visible when the part has been
standard hexagonal nut), the indicated torque
removed. Old RTV sealant must be removed before
applies.
the component is sealed again. Use denatured alco-
hol.
Strength classes
Nuts and bolts are subdivided into different strength Anaerobic agents.
classes. The classification is shown by a marking on These agents cure (harden) in the absence of air.
the bolt head. Markings of a higher number indicate These preparations are used when two solid compo-
stronger material. For example, a bolt marked 10-9 is nents, e.g. two cast components, are fitted together
stronger than one marked 8-8. without a gasket. Common uses are also to lock and
seal plugs, stud threads, taps, oil pressure monitors
For this reason, it is important that when bolts are etc.
removed they are returned to their original locations
on re-assembly. When replacing bolts check the Hardened anaerobic preparations are glassy and for
applicable Spare parts catalogue to ensure the cor- this reason, the preparations are colored to make
rect bolt is used. them visible. Hardened anaerobic preparations are
highly resistant to solvents, and old compound can-
not be removed. On re-assembly, it is important to
carefully degrease and wipe dry components first,
before applying new sealant in accordance with the
instructions.
4 7747622 05-2008
00-0 General
Safety regulations for fluorocarbon The following seals are most probably made from flu-
rubber orocarbon rubber:
Fluorocarbon rubber is a common material in sealing Seal rings for the crankshaft, camshaft, idler shafts.
rings for shafts, and in O-rings, for example.
O-rings, regardless of where they are installed. O-
When fluorocarbon rubber is exposed to high tem- rings for cylinder liner sealing are almost always
peratures (above 300C), hydrofluoric acid can form. made of fluorocarbon rubber.
This is highly corrosive. Contact with the skin can
Please note that seals which have not been
result in severe chemical burns. Splashes in your
exposed to high temperature can be handled nor-
eyes can result in chemical wounds. If you breathe in
mally.
the fumes, your lungs can be permanently damaged.
WARNING!
Ttningar fr aldrig brnnas loss vid demontering
eller eldas upp under okontrollerade former. Risk fr
giftiga gaser.
WARNING!
Anvnd alltid handskar av kloroprengummi
(handskar fr kemikaliehantering) och
skyddsglasgon. Hantera den borttagna ttningen p
samma stt som frtande syra. Alla rester, ven
aska, kan vara starkt frtande. Anvnd aldrig tryckluft
vid rengring.
Lgg gummiresterna i en plastburk som frsluts och
frsetts med varningstext. Tvtta handskarna under
rinnande vatten innan de tas av.
7747622 05-2008 5
03-2 Specifications, Engine
Group 21 Engine
Engine block
Length 986 mm
Height, upper block plane-crankcase center- 623 mm
line
Height lower block plane-crankcase centerline 385 mm
Cylinder head
Type 6 cyl.
Length 849.5 mm
Width 256 (0,2) mm
Height 110 mm
6 7747622 05-2008
03-2 Specifications, Engine
Cylinder liner
Type Wet, replaceable
Height, total 228 mm
Sealing surface height above block plane 0.1 mm
No. of seal rings per cylinder liner 2
Piston
Type Forged piston
No. of ring grooves 3
Piston pin diameter 45 mm
Piston rings
Compression rings
Number 2
Specification Wear tolerance
Piston ring clearance in groove:
Upper
compression ring (trapezium profile)
Lower
Compression ring
0.07 mm 0.105 mm
Piston ring gap, measured at ring opening:
Upper
compression ring
0.3 mm
Lower
compression ring 0.15 mm
1.5 mm 2.0 mm
Maximum piston ring gap, measured at ring
opening:
Upper
compression ring
35.5 mm
Lower
compression ring
35.5 mm
7747622 05-2008 7
03-2 Specifications, Engine
Valve mechanism
Valves
Valve seats
Standard
Outer diameter (A)
Inlet 39.31 mm
Exhaust 36.81 mm
Height (B)
Inlet 7.5 (0.005) mm
Exhaust 7.5 (0.005) mm
8 7747622 05-2008
03-2 Specifications, Engine
Standard
Diameter (C)
Inlet 39.2 mm
Exhaust 36.7 mm
Depth (D)
Inlet/exhaust 11.5 mm
Valve guides
Length
Inlet/exhaust 145.85 mm
Inner diameter
Inlet/exhaust 8 (0.1) mm
Rocker arms
Valve springs
Inlet
Uncompressed length 64.48 mm
Exhaust
Uncompressed length 64.48 mm
Timing gear
No. of teeth
Drive gear, crankshaft 48
Drive gear, camshaft 96
Drive gear, fuel feed pump 23
Drive gear, lubrication oil pump 51
Camshaft
7747622 05-2008 9
03-2 Specifications, Engine
Valve lift
Inlet 6.63 (0.08) mm
Exhaust 7.13 (0.08) mm
Camshaft bearings
Reciprocating components
Crankshaft
Length 976.50 (0.25) mm
Crankshaft, end float* 0.10-0.32 mm
Ovality of main and big end bearings 0.002 mm/10 max 0.05 mm/360
Taper of main and big end bearings Grade 0.005 mm/Parallel 0.008mm
Diameter () standard 85 mm
Undersize
0.25 mm 84.75 mm
0.50 mm 84.50 mm
Oversize
0.4 mm (thrust bearing 0.2) 34.3 mm
Fillet radius (R) 2.5 (0,2) mm
Oversize Oversize
0.2 mm 3.1 mm 0.25 mm 2.85 mm
0.50 mm 2.98 mm
Radial clearance, main bearings max 0.1 mm
10 7747622 05-2008
03-2 Specifications, Engine
Diameter () 75 mm
Undersize
0.25 mm 74.79-74.82 mm
0.50 mm 74.54-74.58 mm
Oversize
0.1 mm 2.60 mm
0.2 mm 2.72 mm
Connecting rod
7747622 05-2008 11
03-2 Specifications, Engine
Common Rail
Safety valve opening pressure 1850-1950 bar
Feed pump
Supply pressure, at 1200 rpm 0.2 MPa (29 psi)
Turbochargers
Charge pressure (1500 rpm) 250 kPa (2.5 bar)
Charge pressure (1800 rpm) 240 kPa (2.4 bar)
Coolant
Volvo Penta anti-freeze, mixed 40/60% with water. See specification below.
Water specification: To avoid the risk of cooling system clogging the coolant must be mixed
with clean water according to ASTM D4985. if there is any doubt regarding the purity of the
water, distilled water must be used, alternatively ready-mixed coolant.
Thermostat
Quantity and type 1 pc. piston thermostat
Opening temperature 83 C (181 F)
Fully open at 103 C (217 F)
12 7747622 05-2008
03-2 Specifications, Engine
Tightening torque
Torque applies to oiled bolts and nuts. Degreased (washed) parts should be oiled prior to assembly.
In those cases where no tightening torques are indicated, Volvo standard torques for the respective thread
dimension and bolt grade must be used.
7747622 05-2008 13
03-2 Specifications, Engine
Special torque
Group 21 Engine
Main bearing
NOTICE! Screws for main bearing caps may only be re-used three times.
Step 1 50 Nm
Step 2 angle tighten 60
Step 3 angle tighten 60
Flywheel
Step 1 30 (5)
5 Step 2 angle tighten 60
2
Step 3 angle tighten 60
7 9
Flywheel housing
3
4 Step 1 (M12) 110 Nm
Step 2 (M8) 30 Nm
8
10 Step 3 (M16) 260 Nm
1
6
P0003164
Cylinder head
NOTICE! Cylinder head bolts may only be re-used five
times.
Step 1 30 Nm
Step 2 angle tighten 60
Step 3 angle tighten 60
Oscillation damper
NOTICE! The screws on the vibration damper may not be re-used.
Step 1 30 (5) Nm
Step 2 angle tighten 60
Step 3 angle tighten 60
14 7747622 05-2008
03-2 Specifications, Engine
Valve cover
Bolt, valve cover 8.5 Nm
Rocker arm bridge 20 Nm
Valve adjustment, lock nuts 20 Nm
Oil pan
Step 1 15 Nm
Step 2 30 (3) Nm
Common Rail 30 Nm
Rail pressure sensor, common rail 70 Nm
Safety valve, common rail 100 Nm
Fuel delivery pipe 25 Nm
Fuel pressure sensor 30 (5) Nm
Fuel pump
Step 1 10 Nm
Step 2 50 Nm
Exhaust manifold
Step 1 15 Nm
Step 2 45 Nm
Inlet pipe 30 Nm
Turbocharger, exhaust manifold 30 (5) Nm
Turbocharger, oil delivery pipe 39 (8) Nm
7747622 05-2008 15
05-1 Safety Instructions
Read the safety information below and the service manual section About this Workshop manual and About
repair instructions carefully before repair and service work is begun.
!
This symbol is used in the service manual and on the product, to call attention to the
fact that this is safety information. Always read such information very carefully.
Safety texts in the manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT! Is used to draw your attention to something that may cause minor dam-
age or a minor malfunction to the product or property.
NOTICE! Is used to draw your attention to important information that will facilitate the
work or operation in progress.
This symbol is used on our products in certain cases and refers to important information
in the instruction book. Make sure that warning and information symbols on the engine
are clearly visible and legible. Replace symbols which have been damaged or painted
over.
A compilation of safety precautions that must be taken and risks which must be paid attention to is
presented in the following pages.
16 7747622 05-2008
05-1 Safety Instructions
Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply to the engine at the main switch ! engine is hot. Steam or hot coolant can spray
(switches) and lock it (them) in the off position out and system pressure will be lost. Open the
before starting work. Post a warning notice at filler cap slowly, and release the pressure in the
the main circuit breaker. cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed when the engine is hot.
As a rule, all service operations must be carried Hot oil can cause burns. Avoid skin contact with
! out with the engine stopped. However, some ! hot oil. Ensure that the lubrication system is not
work, such as adjustments, will require the under pressure before any work is begun.
engine to be running. Approaching an engine Never start or operate the engine with the oil
which is running is a safety risk. Bear in mind filler cap removed, because of the risk of oil
that loose clothing or long hair can fasten in ejection.
rotating parts and cause serious personal
injury.
Be aware of hot surfaces (exhaust pipes, tur- Never start the engine without installing the air
! bos, charge air pipes, starting heaters etc.) and ! filter. The rotating compressor turbine in the tur-
hot fluids in pipes and hoses on an engine that bocharger can cause severe injury. Foreign
is running or has just stopped. objects entering the intake ducts can also cause
If work is done adjacent to a running engine, a mechanical damage. Install all protective cov-
careless movement or a dropped tool may in the ers before the engine is started.
worst case lead to personal injury.
Ensure that the warning symbols or information Only start the engine in a well-ventilated space.
! decals on the product are always clearly visible. ! When running in a confined space, exhaust
Replace decals which have been damaged or fumes and crankcase gases must be led away
painted over. from the engine bay or workshop area.
Avoid getting oil on your skin! Protracted or The majority of chemicals e.g. engine and trans-
! repeated exposure to oil can cause skin to ! mission oils, glycol, gasoline, and diesel oil,
become dry. Irritation, dryness, eczema and together with chemicals for workshop use such
other skin problems may then result. From a as degreasing agents, paints and solvents, are
health standpoint, used oil is more dangerous injurious to health. Carefully read the instruc-
than new. Use protective gloves and avoid oil- tions on the product packaging! Always follow a
soaked clothes and rags. Wash regularly, espe- product's safety directions, e.g. use of protec-
cially before eating. Use suitable barrier creams tive mask, glasses, gloves etc. Ensure that
to counteract drying out of the skin and to aid other personnel are not exposed to substances
dirt removal. that are injurious to health. Ensure good venti-
lation. Handle used and leftover chemicals in
the prescribed manner.
Stop the engine and turn off the electrical supply Clutch adjustments must be carried out with the
! at the main switch(es) before carrying out work ! engine stopped.
on the electrical system.
7747622 05-2008 17
05-1 Safety Instructions
Always use protective glasses or goggles when Never start the engine with the valve cover
! carrying out work where a risk of splinters, ! removed. There is a risk of personal injury.
grinding sparks, splashes from acid or other
chemicals is present. Your eyes are extremely
sensitive; injury may cause blindness!
Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. Marine engines: Close the sea cock / cooling
water inlet valve before work on the cooling sys-
tem is begun.
All fuels, as well as many chemicals, are flam- Make sure that oil, fuel-soaked rags, and used
! mable. Do not allow open flames or sparks in ! fuel and oil filters are stored in a safe manner.
their vicinity. Gasoline, some thinners, and Rags soaked in oil can spontaneously ignite
hydrogen gas from batteries are extremely under certain circumstances. Used fuel and oil
flammable and explosive when mixed with air in filters are environmentally hazardous waste
the correct proportions. No Smoking! Ensure and must be handed to an approved waste
that the work area is well ventilated and take the management facility for destruction, as must
necessary safety precautions before welding or any used lubrication oil, contaminated fuel,
grinding work is begun. Always ensure that paint residue, solvents, degreasers and wash
there are fire extinguishers close at hand in the residue.
work area.
Batteries must never be exposed to open Never work alone when removing heavy com-
! flames or electric sparks. Never smoke in the ! ponents, even when using lifting devices such
vicinity of the batteries; they generate hydrogen as locking tackle lifts. When using a lifting
gas when charged, which is explosive when device, two people are usually required to do
mixed with air. This gas is easily ignited and the work - one to take care of the lifting device
highly explosive. A spark, which can be caused and the other to ensure that components are
by incorrect battery connection, is sufficient to lifted clear and not damaged during the lifting
cause a battery to explode and cause damage. operations.
Never transpose the positive (+) and negative The existing lugs on the engine should be used
! (-) battery posts when installing batteries. Such ! for lifting. Always check that the lifting equip-
a transposition can result in serious damage to ment used is in good condition and has the load
electrical equipment. Refer to the wiring dia- capacity to lift the engine (engine weight includ-
gram. ing gearbox or extra equipment). For safe han-
Always use protective goggles when charging dling and to avoid damaging components fitted
and handling the batteries. Battery electrolyte to the top of the engine, the engine must be
contains sulfuric acid which is highly corrosive. lifted with a correctly adjusted lifting boom. All
Should the battery electrolyte come into contact chains or wires must run parallel to each other
with unprotected skin, wash it off immediately and as perpendicular to the engine as possible.
using soap and copious amounts of water. If you If other equipment attached to the engine has
get battery acid in your eyes, flush at once with altered its center of gravity, special lifting devi-
copious amounts of water and seek medical ces may be needed to obtain the correct bal-
assistance immediately. ance for safe handling. Never perform any work
on an engine that is only suspended from the
lifting equipment.
18 7747622 05-2008
05-1 Safety Instructions
The components in the electrical and fuel sys- Exercise extreme caution when leak-detecting
! tems on Volvo Penta products are designed and ! on the fuel system and testing the fuel injector
manufactured to minimize the risk of fire and nozzles. Use eye protection. The jet from a fuel
explosion. The engine must not be run in areas nozzle has very high pressure and great pene-
where there are explosive materials. tration power. Fuel can force its way deep into
body tissue and cause severe injury. There is a
risk of blood poisoning (septicemia).
Only use fuels and lubricating oils recom- Never use a high-pressure washer for cleaning
! mended by Volvo Penta. Refer to the Operator's ! the engine.
Manual for the product in question. Use of fuels Pay attention to the following when using a high-
that are of a lower grade may damage the pressure washer on components other than the
engine, the injection pump and the injectors. On actual engine: Never direct the water jet at
a diesel engine, low grade fuel can cause the seals, rubber hoses or electrical components.
control rod to bind and the engine to over-rev,
with the risk of engine damage and personal
injury as a result. Low fuel and oil grades may
result in high service, maintenance and repair
costs.
7747622 05-2008 19
08-1 Universal Tools
P0004345
P0004316
P0004315
9985468 Valve spring com- 9985471 Sliding depth gauge 9986485 Stand
pressor
Removal/installation of valve For use when checking valves. For use with e.g. 88800050 Fix-
collets. ture.
P0004355
P0001875 P0002793
20 7747622 05-2008
08-1 Universal Tools
Other Equipment
The following miscellaneous equipment is used when
working on the engine. The equipment can be ordered
from AB Volvo Penta by specifying the number indi-
cated.
Orig
in
al
P0002936 P0002930
1678297 Spacer
For use with 9996398 Manome-
ter.
7747622 05-2008 21
08-2 Special Service Tools
P0004342
P0002784
P0004347
P0002947
22 7747622 05-2008
08-2 Special Service Tools
P0004331
P0004332
P0004333
9996400 Slide hammer 9996645 Puller 9996666 Nipple
Removal of injector pressure For use with cylinder liners. For use with, among other
pipe. things, 9996398 Manometer.
P0004348
P0004349
P0001859
P0004351
P0004352
P0001878
7747622 05-2008 23
08-2 Special Service Tools
P0004338
P0001879
P0004276
24 7747622 05-2008
20-0 Engine Information, General
7747622 05-2008 25
20-0 Engine Information, General
26 7747622 05-2008
20-0 Engine Information, General
P0003292
Cylinder numbering
A = flywheel
A 1 2 3 4 5 6
P0003447
7747622 05-2008 27
20-0 Engine Information, General
28 7747622 05-2008
20-0 Engine Information, General
Location of sensors
7747622 05-2008 29
20-0 Engine Information, General
EMS 2
EMS 2 (Engine Management System) is an electronic system with CAN communication (Controller Area Network)
for diesel engine control. The system was developed by Volvo and includes fuel control and a diagnostic function.
Summary
The system comprises, among other things, a control unit, sensors and injectors. The sensors send input signals
to the control unit, which in turn controls the injectors.
The information from the sensors gives exact data about prevailing operating conditions and allows the processor
in the control module to calculate the correct injection amount, injection timing and check engine health.
Fuel control
The engine fuel requirement is analyzed up to 100 times per second. The amount of fuel injected into the engine
and the injection advance are fully electronically controlled via fuel valves and the unit injectors.
This means that the engine always receives the correct volume of fuel in all operating conditions, which provides
lower fuel consumption, minimal exhaust emissions etc.
Diagnostic function
The task of the diagnostic function is to detect and locate disturbances within the EMS 2 system, to protect the
engine, and to provide information about problems that have arisen.
If a malfunction is detected, it is announced by warning lamps, a flashing diagnostic lamp or in plain language on
the instrument panel, depending on the equipment used. If a fault code is obtained as a flashing code or in plain
language, it is used for guidance in any fault tracing. Fault codes can also be read by Volvos VODIA tool at
authorized Volvo Penta workshops.
If there is a serious malfunction, the engine will be shut down altogether, or the control unit will reduce the power
delivered (depending on application). Once again, a fault code is set for guidance in any fault tracing.
30 7747622 05-2008
20-0 Engine Information, General
Cylinder head
The cylinder head is made of cast iron and is cast in one piece. The thermostat housing is mounted directly on
the cylinder head.
The fuel return channel for the injectors is drilled along the length of the cylinder head and has a machined, ring-
shaped chamber around each injector.
There is a drilled channel for the injector delivery pipe unions. The unions are sealed against the cylinder head
with O-rings.
7747622 05-2008 31
20-0 Engine Information, General
The injector (1) is regulated by the control unit. The injectors are centrally positioned between the four valves and
are held in place by yokes (2).
The valve guides (3) are made from cast iron alloy. Valve stem seals are fitted to the valve guides.
32 7747622 05-2008
20-0 Engine Information, General
Cylinder block
The cylinder block is made of cast iron and cast in one piece.
All oil channels are machined directly in the block. There are two longitudinal oil channels: the right side of the
block, seen from the front, is the piston cooling channel and on the left side is the main oil channel. Both channels
are plugged
7747622 05-2008 33
20-0 Engine Information, General
The vertical cross section (A) shows the position of the cylinder liner and unit pump in the block.
The camshaft (1) is located on the right side of the cylinder block.
All the camshaft bearings are the same size. To render faulty main bearing cap positioning impossible, there is
a boss cast into the block (3) and an equivalent boss on the main bearing cap. The main bearing caps are
furthermore marked with the numbers 1-7 from the rear of the engine. The underside of the bearing cap has an
arrow showing the flywheel rotation direction.
The location of the unit pumps is shown both in the vertical cross section (A2) and the horizontal cross section
(B4).
34 7747622 05-2008
20-0 Engine Information, General
Oil pan
The oil pan is a die-cast metal laminate with a volume of about 24 liters.
Sealing is achieved with silicon. The oil pan is attached with 34 bolts.
7747622 05-2008 35
20-0 Engine Information, General
Sealing joints
TAD734GE has wet cylinder liners. They are sealed against the cylinder block with a direct seal at the liner collar
and two rubber ring seals at the lower edge. The sealing rings are made from the same material and have the
same color. The liner's sealing surface against the gasket is convex.
The gasket between the cylinder head, block and liner is made from steel and has vulcanized rubber seals for
the coolant and oil channels. The thickness of the gasket is determined by one to three holes, where one hole
represents the thinnest gasket. The marking holes are located next to the hole for the cylinder head oil supply.
36 7747622 05-2008
20-0 Engine Information, General
To facilitate assembly and to achieve an exact positioning of the cylinder head onto the cylinder block, two cylin-
drical guide pins are fitted to the block. There are two corresponding guide holes in the cylinder head.
7747622 05-2008 37
20-0 Engine Information, General
The engine has pistons cast in aluminum alloy. The lower edge of the skirt has a "recess" for piston cooling (1).
The piston has two compression rings and one oil scraper.
The upper compression ring (2) is of Keystone type with a trapezoid section. The lower compression ring (3) has
a rectangular section with a chamfered lower edge. The oil scraper (4) is spring loaded.
The valve guides (5) are made from cast iron alloy.
The conrod is forged and split at the lower end (big end) using a method known as fracture splitting. The upper
end (little end) has a bush (6) lubricated via a drilled channel (7). Each connecting rod is marked on both parts
(8).
38 7747622 05-2008
20-0 Engine Information, General
The camshaft is induction hardened and is supported in seven main bearings with interchangeable bearing shells.
Between each bearing cap there are two cams: an inlet and an exhaust cam. The exception is by the two unit
pumps, where there are three cams: an inlet, an exhaust and a unit pump cam. The unit pumps are staggered at
120 intervals in relation to one another.
The camshaft is driven directly by the crankshaft. The camshaft and drive gear are a single unit, since the gear
is shrink-fitted in place.
The camshaft sensor lugs are located within the gear wheel. There are seven sensor lugs, of which six handle
sensor signals and one acts as a zero-setting lug.
The engine valve mechanism works according to the pushrod principle. Power transfer from the camshaft to the
push rods takes place via roller cams. During rotation, the roller-follower roller moves back and forth transversely
on the cam. This minimizes wear. The unit pumps are also operated by roller followers.
7747622 05-2008 39
20-0 Engine Information, General
The crankshaft is supported in seven main bearings with interchangeable bearing shells (1).
The main bearing caps are furthermore marked with the numbers 1-7 from the rear of the engine. The second
main bearing from the rear also houses the thrust bearing, comprising four half-moon shaped washers.
The thrust bearing in the cylinder block (2) has no pins while the thrust bearings in the caps (3) have pins for
easier fitting.
40 7747622 05-2008
20-0 Engine Information, General
The crankshaft and drive gear are a single unit, since the gear is shrink-fitted in place. The oil pump drive is located
at the front end of the crankshaft. There is a machined surface in front of the drive gear, on which the crankshaft
seal sit s against the oil pump housing. The gear that drives the camshaft is located at the rear end of the crank-
shaft. There is a machined surface behind the drive gear, on which the crankshaft seal sits against the flywheel
housing.
The crankshaft is lubricated via separate channels in the cylinder block feeding each main bearing. Each crank-
shaft cap has a bored channel. from which a channel is drilled to the closest big end journal.
The oscillation damper is hydraulic and is bolted directly onto the front crankshaft flange. The damper is also used
as as a multi-grooved belt pulley. The flywheel is bolted to the rear crankshaft flange with ten bolts. The flywheel
is fixed to the crankshaft with a guide pin. The ring gear is replaceable. There are milled grooves on the periphery
for the flywheel sensor.
7747622 05-2008 41
20-0 Engine Information, General
Timing gear
1 Crankshaft gear
2 Camshaft gear
3 Fuel pump drive
4 Flywheel housing alignment
The engine timing gears are located between the engine block and flywheel housing at the rear of the engine.
The crankshaft drives the camshaft gear and the camshaft gear drives the fuel pump gear. The crankshaft flange
overlaps the camshaft gear.
The seal between the flywheel housing and engine block is made with sealant.
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The crankshaft and camshaft are aligned by placing the punch mark on the camshaft gear in line with the marking
on the crankshaft flange.
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Housings
The engine has two housings. At the front end the drive gear between the crankshaft and the oil pump is protected
by a cover into which the oil pump is integrated. At the rear end, the timing gears are covered by the flywheel
housing.
The crankshaft is sealed against the housings with oil seals.
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Oil pump
The oil pump is a gear pump with a rotating inner ring. It is integrated into the oil pump cover at the front of the
engine and is driven by a gear on the crankshaft. A safety valve is fitted in the oil pump cover directly after the oil
pump.
The oil strainer supplies oil to the pump. The strainer is connected to the oil pump via a pipe and gasket.
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The oil pressure sensor is mounted in the oil filter housing and measures the pressure entering the engine. Oil
flow to the engine is regulated by three valves located in the oil filter housing.
1 Oil filter check valve. The function of the valve is to prevent oil draining out from the filter housing when the
engine stops.
It also provides back pressure to the oil pump.
2 By-pass valve, which regulates system pressure. Oil is returned to the oil pan.
3 Oil cooler by-pass valve. The valve has a by-pass function.
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Oil cooler
The oil cooler is mounted directly under the oil filter housing. It is a reverse-flow cooler where the oil is transported
backwards and water forwards.
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The piston cooling nozzle is aimed so that the oil spray reaches the underside of the piston crown. The piston
skirt has a recess for the piston cooling nozzle.
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The hand pump unit (1) has a hand pump (2), which is used to purge the fuel system.
The pre-filter is fitted beneath the hand pump unit (3). The water separators lower part is fitted to the pre-filter
(4), along with a drain nipple (5) and a sensor (6).
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The feed pump is a gear pump driven by the camshaft. It is located on the right side of the flywheel housing.
The pump has an integrated by-pass valve to maintain the correct flow and pressure in the fuel system. The by-
pass valve is not replaceable.
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Fuel filter
The fuel filter housing comprises a filter and two valves. At the very top of the filter there is a by-pass valve and
beneath the filter there is a valve which automatically drains the housing when the filter is removed.
The feed pressure sensor is fitted in the fuel filter housing.
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Unit pumps
The fuel system contains two unit pumps that are driven by roller followers activated by the camshaft. Their
purpose is to pressurize the fuel system.
The high pressure and low pressure sides of the unit pumps are hydraulically separated. The unit pumps require
a pressure of at least 1.7 bar in order to work.
NOTICE! Unit pumps are very sensitive to dirt particles.
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The common rail (1) has an inner volume of 35 cm 3 and is used to store pressurized fuel for the injectors. The
common rail has a pressure sensor (2) and a safety valve (3) that opens at a pressure of about 1850-1950 bar.
The safety valve protects the high pressure side of the fuel system against excess pressure. If a safety valve
opens, the pressure drops to about 650-850 bar.
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The pressurized fuel passes through a union in the cylinder head, via the injector delivery pipe to the injector.
Fuel is fed to the injector via a metallic seal between the injector delivery pipe and the injector.
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P0003286
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The exhaust manifold is made in three parts in heat-resistant cast steel. The joints are sealed with sealing rings.
Between the cylinder head and the manifold flanges, there are gaskets made from graphite coated sheet steel.
The turbocharger has a turbine with a by-pass and is a MWE-type (Map Width Enhancement). The compressor's
air inlet is divided into an inner and outer area, connected via a ring-shaped chamber.
The by-pass valve on the exhaust side is designed to protect the turbo by reducing its speed at high power levels.
The valve is influenced by the turbo pressure via an actuator and a lever.
A Exhaust flow at low turbo pressure is shown here. The valve is closed and the entire exhaust flow is through
the turbine rotor.
B When the turbo pressure reaches a certain level, the valve starts to open. Some of the exhaust gases flow
via the valve and by-pass the turbine thus reducing turbine revolutions.
C When the engine is working hard at low speed, the air that the engine cannot use is recirculated via the ring-
shaped chamber.
D At high engine speed and high turbo pressure, the entire inlet area is used, which provides more air to the
engine. The turbo thus has a broader working range and engine torque is improved.
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Cooling System
The coolant pump pumps coolant into the cylinder block via the oil filter housing. In the oil filter housing the coolant
passes both through the oil cooler and the oil cooler's cooling jacket. The cylinder liners are cooled in the cylinder
block.
The cylinder block is supplied with coolant through both the return coolant from the liner jacket and via drilled
channels. All coolant flows via the thermostat to the radiator or back to the coolant pump, depending on engine
temperature.
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The thermostat housing is made from cast iron and is located on the front of the cylinder head. The thermostat
opens at 84C.
The rear section of the coolant pump is machined directly in the oil filter housing and the oil cooler is mounted on
the underside of oil filter housing.
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Drive belt
The fan is driven by a separate drive pulley (1). The drive belt (2) drives the fan, the alternator and the coolant
pump (3) via an idler wheel (4) and a belt tensioner (5).
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Engine
Engine Fixture, Installation
885510 Plugs
9986485 Stand
88800050 Fixture
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2 Remove:
- turbocharger pressure pipe (2), to the
charge air cooler
- oil delivery pipe (3) and oil return pipe (4)
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Removal
1 Remove:
- the induction hose (1)
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2 Remove:
- turbocharger pressure pipe (2), to the
charge air cooler
- oil delivery pipe (3) and oil return pipe (4)
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19 Remove:
- drive belt
- fan
- fan bearing, with belt pulley
- fan bearing holder
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25 Remove:
- the alternator
- the belt tensioner, with drift (1)
- idler wheel, at the alternator
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P0003308
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Flywheel, removal
39 Remove the engine rpm sensor from the flywheel
housing. Crank the engine 90.
Remove any plastic plugs used for locking the
flywheel bolts, from between every alternate bolt.
Remove the flywheel bolts. Use tool 8880 0014
as a counterhold.
40 Attach suitable lifting eyes and straps to achieve
the correct balance for lifting.
Lift the flywheel away.
CAUTION!
Heavy object. Use lifting device when installing or
removing.
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Crankshaft
46 Check that the camshaft and crankshaft drives
are marked (otherwise mark them).
Rotate the engine so that the crankshaft faces up.
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Cylinder, measuring
52 Set the dial indicator to 108 mm.
Use dial indicator 998 9876.
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Installation
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P0003227
Crankshaft, installation
8 Lower in the crankshaft. The marks must be
aligned.
Use a ruler to check that the marks are aligned
through the crankshaft and camshaft centers.
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Step 1 50 Nm
Step 2 60
Step 3 60
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Pistons, installation
20 Temporarily remove the installation tool (8880
0129) holding the cylinder liner where the piston
is to be installed. When the piston is in position
the tool must be put back again.
Step 1 30 Nm
Step 2 60
Step 3 30
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Flywheel, installation
27 Clean the surfaces on the flywheel and crank-
shaft.
2 5 CAUTION!
7 9 Heavy object. Use lifting device when installing or
removing.
3 Offer the flywheel into place and align it with the
4
guide pin. Tighten the bolts by hand.
8 Remove the flywheel plug (for the cranking tool).
10 Use tool 8880 0014 as a counterhold.
1
6
Tighten the bolts in the sequence illustrated:
Step 1 30 (5) Nm
P0003164
Step 2 60
Step 3 60
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P0003308
Torque to: 30 Nm
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41 Oil the cylinder head bolts (M12) and let them drip
off.
Install the cylinder head bolts.
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Injectors, installation
47 Install the injectors and injector yokes.
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48 IMPORTANT!
Innan insprutarna stts dit mste frbrnnings-
rester noggrant torkas bort frn cylinderhuvudets
lopp. Sug bort smutspartiklar.
Always use a new O-ring and a new washer.
Torque to: 4 Nm
Then loosen the bolt (1) somewhat.
Torque to: 20 Nm
Torque to: 23 Nm
Connect the electrical wiring (2) to the injectors.
Torque to: 52 Nm
Torque to: 39 Nm
Install new fuel delivery pipes (tool 888 000 70).
Torque to: 25 Nm
61 Install:
- speed sensor, camshaft (11)
- Speed sensor, flywheel (10)
74 Install:
- fan bearing holder
- fan bearing, with belt pulley
- fan
- drive belt
WARNING!
Pinch hazard.Keep fingers clear.
Torque to: 30 Nm
Torque to: 39 Nm
Install the turbocharger oil return pipe (4) with a
new gasket and a new O-ring.
Torque to: 20 Nm
Install the turbocharger pressure pipe (2) to the
charge air cooler using new O-rings.
80 Install:
- the induction hose (1)
After installation:
- Fill with coolant, purge the system.
- Fill with fuel, purge the system.
- Connect all electrical connections.
Removal
1 Remove:
- air cleaner
- inlet hose (1)
2 Remove:
- charge air pipe (2) to the charge air cooler
- oil delivery pipe (3) and oil return pipe (4)
- exhaust manifold, complete with turbo-
charger
16 Remove:
- drive belt
- fan
- fan bearing, with belt pulley
- fan bearing holder
Installation
27 Oil the cylinder head bolts (M12) and let them drip
off.
Install the cylinder head bolts.
Injectors, installation
33 Install the injectors and injector yokes.
34 IMPORTANT!
Innan insprutarna stts dit mste frbrnnings-
rester noggrant torkas bort frn cylinderhuvudets
lopp. Sug bort smutspartiklar.
Always use a new O-ring and a new washer.
Torque to: 4 Nm
Then loosen the bolt (1) somewhat.
Torque to: 20 Nm
Torque to: 23 Nm
Connect the electrical wiring (2) to the injectors.
Torque to: 52 Nm
Torque to: 30 Nm
Connect the fuel hose to the rail.
Torque to: 25 Nm
Install:
- the connector from M-prop (3).
- the connector to the rail pressure sensor
(2).
- the return line connection (1).
43 Install the thermostat housing with new seals.
45 Install:
- fan bearing holder
- fan bearing, with belt pulley
- fan
- drive belt
49 Install:
- exhaust manifold, complete with turbo-
charger
- oil delivery pipe (3) and oil return pipe (4)
- charge air pipe (2) to the charge air cooler
50 Install:
- inlet hose (1)
- air cleaner
Wear limits:
Inlet valve 0.10 mm
Exhaust valve 0.13 mm
5 Install:
- valve
- valve spring
- valve washer
- valve collets
IMPORTANT!
Rengr runt vetilkpan med kallavfettnignsmedel och
bls rent med tryckluft. Speciellt viktigt r det att
rengra mellan inloppsrr och ventilkpa.
1 Remove the oil trap.
Torque to: 20 Nm
(Use a 13 mm box wrench.)
Hold fast the adjusting screw, so that it does not
rotate when torqueing.
Removal
1 Remove the expansion tank cover and remove
the drain nipple protective cap (beneath the radi-
ator).
Connect drainage hose 999 6049 to the nipple.
Drain the coolant.
3 Remove:
- the radiator hoses from the coolant pump
- the radiator hoses from the thermostat hous-
ing
WARNING!
Pinch hazard.Keep fingers clear.
9 Remove:
- the fan
- drive belt
- the belt tensioner
Installation
16 Lubricate the lip of the seal with engine oil.
21 Install:
- belt tensioner
- drive belt
- fan belt
WARNING!
Pinch hazard.Keep fingers clear.
23 Install:
- radiator assembly
- right radiator stay (1)
- left radiator stay (2)
26 Install:
- the charge air cooler hose (upper)
- the radiator hoses to the thermostat housing
- the radiator hoses to the coolant pump
Removal
1 Remove the plug from the flywheel.
Fit cranking tool 88800014.
Fit a socket to the cranking tool and use it as a
stop.
2 5
7 9
3
4
8
10
1
6
P0003164
P0003165
P0003165
8
10
1
6
P0003164
Installation
5 Install a new filter (3) and a new O-ring (2).
6 Install the filter cover (1) and filter.
Torque to: 25 Nm
7 Fill with required volume of oil, see Technical
data.
Removal
1 Remove the engine protection panels:
- lower protection panel (1)
- the four bolts (2) which hold together the two
protection panel halves
- the two clamps for the coolant hose
- the four bolts for the protection panels, on
the right side of the engine
- remove the right protection panel
Installation
13 Replace the oil cooler in the oil filter housing using
new seals.
Torque to: 30 Nm
Torque to: 30 Nm
Torque to: 30 5 Nm
WARNING!
Pinch hazard.Keep fingers clear.
Removal
1 Remove the oil trap.
Installation
6 Check that there is no damage to the lobe/cam.
Torque to: 34 Nm
12 Install new copper washers to the banjo fitting
(2).
Torque to: 26 Nm
13 Install new fuel delivery pipes (tool 888 000 70).
Torque to: 25 Nm
14 Install the fuel return line with new copper wash-
ers (3).
Torque to: 39 Nm
Removal
1 Clean around the pre-filter and the water separa-
tor.
Open the drain nipple in the base of the water
separator (1).
2 Tighten the drain nipple (1).
Remove the lower part of the water separator
(2).
Remove the pre-filter (3); use tool 999 9179.
3 Clean the mating surfaces.
Installation
4 Grease the gasket surfaces.
Fit the new pre-filter (3).
Tighten according to the instructions on the filter.
5 Install the lower part of the water separator (2).
Installation
6 Install a new filter (3) and a new O-ring (2).
7 Install the filter cover (1) and filter.
Installation
5 Install a new O-ring on the fuel feed pump.
Install the fuel feed pump and tighten the three
bolts (1).
6 Install:
- fuel pipe (1), to the pump.
- the clamp (2), for the oil pipe.
Removal
1 Disconnect battery power.
Remove the oil trap.
Installation
8 Install the new injectors together with yokes.
9 IMPORTANT!
Innan insprutarna stts dit mste frbrnnings-
rester noggrant torkas bort frn cylinderhuvudets
lopp. Sug bort smutspartiklar.
Always use a new O-ring and a new washer.
Torque to: 4 Nm
Then loosen the bolt (1) somewhat.
Torque to: 20 Nm
Torque to: 23 Nm
Connect the electrical wiring (2) to the injectors.
Torque to: 52 Nm
Torque to: 25 Nm
IMPORTANT!
Tryckrr mste alltid bytas till nytt efter borttagn-
ing.
Removal
1 Remove the oil trap.
Remove the fuel delivery pipe. Plug (plugs 885
510) the connections against dirt entry.
Undo the fuel hose connections.
Torque to: 70 Nm
Installation
7 Install the Common Rail unit.
Torque to: 25 Nm
Removal
1 Disconnect battery power.
Remove the pressure pipes (1).
Installation
3 Align the injector pressure line and insert it into
the holder so that the balls (1) align with the
grooves (2) in the holder.
IMPORTANT!
Spridartryckrret mste alltid vara nytt.
Torque to: 20 Nm
Torque to: 52 Nm
6 Install new delivery pipes (1). Use wrench 8880
0070.
Torque to: 25 Nm
IMPORTANT!Tryckrr mste alltid bytas till nytt
efter borttagning.
3 Install:
- the control valve
- return line (4)
- the feed line from the fuel filter (3)
- feed line (2)
- the cable to the control valve's
MPROP (1) (use a new cable tie)
Installation
6 Assemble the induction manifold with pre-heater.
7 Install the induction manifold with pre-heater
using new gaskets.
8 Torque the bolts to 30 Nm. (Tightening sequence
as illustrated).
Removal
1 Remove:
- the inlet hose (1)
2 Remove:
- turbocharger pressure pipe (2), to the
charge air cooler
- oil delivery pipe (3) and oil return pipe (4)
Installation:
6 Install the exhaust manifold with new gaskets and
new bolts.
Torque to: 30 Nm
Torque to: 39 Nm
Install the turbocharger oil return pipe (4) with a
new gasket and a new O-ring.
Torque to: 20 Nm
Install the turbocharger pressure pipe (2) to the
charge air cooler using new O-rings.
9 Install:
- the inlet hose (1)
25-5 Turbocharger
Turbo, Change
The working method requires removal of the exhaust
manifold.
Removal
1 Remove:
- the inlet hose (1)
2 Remove:
- turbocharger pressure pipe (2), to the
charge air cooler
- oil delivery pipe (3) and oil return pipe (4)
Installation
5 Install the turbocharger with a new gasket.
Torque to: 30 Nm
Torque to: 39 Nm
Install the turbocharger oil return pipe (4) with a
new gasket and a new O-ring.
Torque to: 20 Nm
Install the turbocharger pressure pipe (2) to the
charge air cooler using new O-rings.
Checks
1 Remove the plug from the charge air pipe.
Fit nipple 999 6666.
Installation
3 Remove tools (999 8339, 999 6666).
Refit the plug on the charge air pipe.
Installation
3 Replace the air filter housing inner part.
Install a new air filter.
Pre-heating, Change
Disconnect power to the engine.
Removal
1 Remove the "upper" hose from the charge air
pipe.
2 Remove the wiring (1) from the pre-heater.
4 Remove:
- lower protection panel (1)
- the four bolts (2) which hold together the two
protection panel halves
- left protection panel
Installation
7 Install the pre-heater with new gaskets.
Removal
1 Remove the expansion tank cover and remove
the drain nipple protective cap (beneath the radi-
ator).
Connect drainage hose 999 6049 to the nipple.
Drain the coolant.
Installation
8 Install the radiator assembly, and the left radiator
stay (2).
9 Install the right radiator stay (1).
12 Install:
- the charge air cooler hose (upper)
- the radiator hoses to the thermostat housing
- the radiator hoses to the coolant pump
Removal
1 Remove the expansion tank cover and remove
the drain nipple protective cap (beneath the radi-
ator). Connect drainage hose 999 6049 to the
nipple.
Drain the coolant.
WARNING!
Pinch hazard.Keep fingers clear.
Installation
8 Install the coolant pump; first guide in the coolant
pump "neck" and O-rings.
Use a new gasket and new O-rings.
Torque to: 30 5 Nm
Torque to: 30 5 Nm
Connect the alternators cable connectors, and re-
install the wiring clamp (2).
WARNING!
Pinch hazard.Keep fingers clear.
Thermostat, Change
9992564 Drift
9996049 Draining hose
9998511 Lever
Removal
1 Remove the engine protection panels:
- lower protection panel (1)
- the four bolts (2) that hold together the two
protection panel halves
- the two clamps that hold the coolant hose
- the four bolts for the protection panels, on
the right side of the engine
- remove the right protection panel
Installation
7 Clean the seal ring contact surfaces in the ther-
mostat housing (scrape clean).
Install the seal ring with the aid of drift 999 2564
and a small mallet.
32-1 Alternator
Alternator, Change
Alternator, general
The alternator is belt driven and mounted at the front
right of the engine.
Removal
1 Disconnect power to the engine.
2 Remove the engine protection panels:
- lower protection panel (1)
- the four bolts which hold together the two
protection panel halves (2)
- the two clamps that hold the coolant hose
- the four bolts for the protection panels, on
the right side of the engine
- remove the right protection panel
WARNING!
Pinch hazard.Keep fingers clear.
Installation
7 Install the alternator and tighten the bolts (1) to
30 5 Nm.
8 Connect the alternator cable connectors, and re-
install the wiring clamp (2).
WARNING!
Pinch hazard.Keep fingers clear.
Removal
1 Disconnect power to the engine.
2 Remove the heat shield.
Undo the starter motor cable connections.
Installation
4 Fit the starter motor.
5 Install the starter motor cable connections.
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Date: ............................................................
Name: ..........................................................
AB Volvo Penta
Customer Support
Dept. 42200
SE-405 08 Gothenburg
Sweden
7747622 English 05-2008
Workshop Manual I
Group 30 4(0)
TAD650VE, TAD660VE,
TAD734GE, TAD750VE, TAD760VE
Group 30 Electrical system
Industrial Engines
Contents
Safety rules ............................................................ 3 Sensor, common rail pressure (fuel) ................... 16
Sensor, fuel pressure ......................................... 16
General information .............................................. 4 Magnetically controlled proportional valve
About this Workshop Manual ............................... 4 (MPROP) ........................................................... 17
Spare parts .......................................................... 4 Water in fuel switch, secondary fuel filter .......... 17
Certified engines .................................................. 4 Switch, coolant level .......................................... 17
Preheater ........................................................... 18
Repair instructions ................................................ 5 Engine control unit, EMS 2 ................................ 18
Our common responsibility ................................... 6
Tightening torques ............................................... 6 Repair instructions .............................................. 19
General advice on working with EMS engines .... 19
Special tools ......................................................... 7 Electric welding .................................................. 20
Changing the engine control unit ........................ 21
EMS 2 - Engine Management System .............. 8 Reprogramming a control unit ............................. 22
General information .............................................. 8 Programming an empty control unit .................... 23
CAN - Controller Area Network ............................. 8 Fault tracing of cables and connectors ............... 24
CIU - Control Interface Unit .................................. 9 Checking the starter motor voltage ..................... 26
DCU - Display Control Unit ................................... 9 Checking the charging system ........................... 27
Fuel control ........................................................ 10 Rail pressure measurement................................ 28
Calculation of fuel quantity ................................. 10
Altitude correction .............................................. 10 Malfunctions ........................................................ 29
Diagnostic function ............................................ 10 Fault code information ........................................ 29
FMI table / SAE standard .................................. 30
Component location ........................................... 11 Manual fault tracing in bus cables ...................... 33
TAD 650, 660, 750, 760 VE ............................... 11
TAD 734 GE ...................................................... 12 Diagnostic Trouble Codes .................................. 34
MID 128, PID 45
Component description ...................................... 13 Inlet air heater status ......................................... 34
Starter motor ...................................................... 13 MID 128, PID 94
Fuel pressure ..................................................... 37
Alternator ........................................................... 13
MID 128, PID 97
Injectors ............................................................. 14
Water in fuel ....................................................... 43
Speed sensor, crankshaft .................................. 14
MID 128, PID 100
Speed sensor, camshaft .................................... 14 Oil pressure ....................................................... 46
Sensor, boost pressure/ MID 128, PID 105
boost temperature .............................................. 15 Boost temperature ............................................. 52
Sensor, oil pressure, engine ............................... 15 MID 128, PID 106
EGR ................................................................... 15 Boost pressure ................................................... 58
Coolant temperature sensor ............................... 16
MID 128, PID 108 MID 128, SID 254
Ambient air pressure .......................................... 64 Controller error .................................................. 132
MID 128, PID 110 MID 128, PSID 96
Coolant temperature ........................................... 66 Rail pressure system ........................................ 133
MID 128, PID 111 MID 128, PSID 97
Coolant level ...................................................... 72 Rail pressure release valve ............................... 137
MID 128, PID 158 MID 128 / MID 144, PSID 201
Battery voltage ................................................... 76 J1939 communication bus ................................ 141
MID 128, PID 164
Rail pressure ...................................................... 78 Engine protection .............................................. 144
MID 128, PID 190 TAD 650, 660, 750, 760 VE .............................. 144
Engine speed ..................................................... 84 TAD 734 GE ..................................................... 145
MID 128 / MID 144, PPID 4
Start input CIU ................................................... 85 Wiring diagrams ................................................. 146
MID 128 / MID 144, PPID 6 Wiring diagram EMS 2:
Engine stop switch ............................................. 87 Vechicle harness TAD 650-760VE ................... 146
MID 128, PPID 19 Engine harness TAD 650-760VE ...................... 147
Internal EGR status ........................................... 89 Engine harness TAD 734GE ............................ 148
MID 128, PPID 55 Wiring diagram DCU .......................................... 149
EMS temperature ............................................... 93 Wiring diagram CIU ........................................... 150
MID 128, PPID 98
Engine sync acknowledge .................................. 95
Technical data .................................................... 151
MID 128 / 144, PPID 132
Switch, water in fuel .......................................... 151
Throttle input request failure, DCU/CIU .............. 97
Sensor, fuel pressure ........................................ 151
MID 128, SID 1-6
Speed sensor, camshaft /
Injector common rail # 1-6 ................................. 100
Speed sensor, crankshaft ................................. 151
MID 128, SID 21
Sensor, oil pressure .......................................... 151
Speed sensor camshaft .................................... 105
Sensor, rail pressure ......................................... 151
MID 128, SID 22
Speed sensor, crankshaft ................................. 110 Combination sensor,
boost pressure/boost temperature ..................... 152
MID 128, SID 39
Sensor, coolant temperature ............................. 152
Engine starter relay ........................................... 115
Switch, coolant level ......................................... 152
MID 128, SID 42
Injection control pressure regulator .................... 118 Alternator .......................................................... 152
MID 128, SID 70 Starter motor ..................................................... 152
Preheat sense ................................................... 122
MID 128, SID 211 Index ................................................................... 153
5V sensor supply 2 ........................................... 124
MID 128, SID 231 References to Service Bulletins ........................ 153
Communication fault J 1939 .............................. 126
MID 128, SID 232
5V sensor supply 1 ........................................... 129
MID 128, SID 240
Program memory .............................................. 131
Safety rules
3
Group 30: Electrical system General information
General information
4
Group 30: Electrical system Repair instructions
Repair instructions
The working methods described in the workshop man- In some cases special safety precautions and user in-
ual apply to work carried out in a workshop. For this structions may be required in order to use the tools and
reason, the engine is lifted out and mounted on an en- chemicals mentioned in the Workshop Manual. These
gine support. Unless otherwise stated reconditioning rules must always be observed, so there are no special
work which can be carried out with the engine in place instructions about this in the workshop manual.
follows the same working method.
By following these basic recommendations and using
The warning signs which occur in the workshop manual common sense it is possible to avoid most of the
(please refer to Safety information for their meanings). risks involved in the work. A clean work place and a
clean engine will eliminate many risks of personal
WARNING! injury and engine malfunction.
Above all, when work on fuel systems, lubrication
systems, inlet systems, turbocharger, bearing caps
IMPORTANT! and seals is done, it is extremely important that no
dirt or other kinds of foreign particles are able to get
in, since this would otherwise cause malfunctions or
NOTE! shortened repair life.
5
Repair instructions Group 30: Electrical system
6
Special tools Group 30: Electrical system
Special tools
9999324 9998482
9998699 88890016
3838619 VODIA complete diagnostic tool.* 885675 Adapter cable for sensor test
Components: 9812519 Multimeter
3838620 VODIA palmtop computer (PDA) with SD card. 9999324 Terminal crimping tool
3838621 VODIA docking station. Used with VODIA PDA
(3838620).
9998482 Gauge for connector on control unit
3838622 VODIA cable with connector. Used with dock- 9998699 Measurebox
ing station (3838621) on the engines communi-
88890016 Adapter cable
cation connector.
*Note. More detailed information about using the VODIA tool can
be found in the tools instruction manual.
7
EMS 2 - Engine Management System Group 30: Electrical system
General information
EMS 2 is an electronic system with CAN communication (Controller Area Network) for diesel engine control. The
system has been developed by Volvo and includes fuel control and diagnostic function.
The system consists of a control module, six injectors, a number of sensors that supply the control module with
measurements, sockets for diagnosis and functional checks. The engine can be connected to a communications
interface consisting of a CAN link and a serial link.
8
Group 30: Electrical system EMS 2 - Engine Management System
9
EMS 2 - Engine Management System Group 30: Electrical system
10
Group 30: Electrical system Component location
1 7
10
11
11
Component description Group 30: Electrical system
12
Group 30: Electrical system Component description
Component description
Starter motor
The starter motor is installed in the flywheel housing,
on the left-hand side of the engine. The starter motor
relay is positive connected, which means that the re-
lay is connected to battery voltage.
Alternator
The alternator is belt driven and mounted on the front
of the engine, on the right.
13
Component description Group 30: Electrical system
Injectors
The injectors are installed on the cylinder head.
The amount of fuel injected and injection duration is
controlled by the engine control unit, via electromag-
netically controlled fuel valves in the injectors. This
means that the engine always receives the correct
volume of fuel in all operating conditions, which offers
lower fuel consumption, minimal exhaust emissions
etc.
14
Group 30: Electrical system Component description
15
Component description Group 30: Electrical system
16
Group 30: Electrical system Component description
17
Component description Group 30: Electrical system
18
Group 30: Electrical system Repair instructions
Repair instructions
19
Repair instructions Group 30: Electrical system
Electric welding
1. NOTE! Cut the current with the main switch.
20
Group 30: Electrical system Repair instructions
21
Repair instructions Group 30: Electrical system
Action:
1. Log in to Volvo Penta Partner Networks web- 8. The next control unit is the vehicle ECU.
site:
Select Electrical system and instruments in the
www.vppn.com VODIA menu.
Select MID 144 ECU, programming.
2. Choose VODIA in the left-hand menu. VODIA will guide you through the entire program-
ming process.
3. Choose ECU programming in the left-hand
menu. 9. NOTE! Programming must be reported back to
Volvo Penta within 28 days. Log in to Volvo Pen-
ta Partner Networks web site:
4. Follow the instructions under Download soft-
ware. Choose the control units to be repro- www.vppn.com
grammed and click the Download button. The
software for the control units is now downloaded
10. Choose VODIA in the left-hand menu.
to the PDA*.
* Note. PDA = Personal Digital Assistant (palmtop computer).
11. Choose Report software in the left-hand menu.
5. Take a look under Settings, Software informa-
tion in VODIA to check that the software has 12. Follow the instructions for Report software/pa-
been downloaded. rameter. Click Report software/parameter.
22
Group 30: Electrical system Repair instructions
Programming an empty
control unit
When a new engine control unit is installed, where no
software has been downloaded, the control unit must
be programmed.
The new control unit must have the same part number
as the old control unit. If the control units do not have
the same part number, it will not be possible to pro-
gram the new control unit until a Conversion kit has
been ordered from Volvo Penta.
If the control units have the same part number, the
new control unit can be programmed as usual. Please
refer to Programming a control unit.
23
Repair instructions Group 30: Electrical system
24
Group 30: Electrical system Repair instructions
1
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.
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. 999 9324.
5
Carefully heat the joint with a hot air gun, to make the
insulation shrink and seal tightly.
25
Repair instructions Group 30: Electrical system
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 disassembly.
8
Install the connector in the reverse order to disassembly.
9
Check that the connector and the mating connector on
the engine control unit or power supply unit are clean
and dry.
10
Join up the multi-pin connector. Please refer to Con-
trol unit, changing for advice on joining up the connec-
tor.
11
Start the engine and check carefully that no fault
codes occur.
General
If battery voltage falls below 24.7 V*, the starter motor
will not be able to crank the engine at normal speed.
A fully charged battery has an open circuit voltage of
about 25.4 V.
* Note. Measured on the batteries.
2
Turn the main switch on.
3
Check that the voltage between terminal B+ on the start-
er motor and battery negatives connection point is the
same as the battery voltage.
26
Group 30: Electrical system Repair instructions
NOTE! It is the consumers (batteries included) which 3. Check the conditions of all cables in the charging
decides the output current from the alternator. system.
4. Regulator fault, try another alternator.
when undercharge
1. Check the alternator belt tension.
2. Check that all connectors at the alternator and at
Measurements
the battery is correct assembled.
1. Engine off.
3. Check the conditions of all cables in the charging
2. Use multimeter 9812519 to do a voltage measure- system.
ment over the battery. The nominal voltage over a
4. Regulator fault, try another alternator.
full loaded battery is approx. 25.4V.
3. Engine on. Run at 1500 rpm.
when overcharge
4. Use multimeter 9812519 to do a voltage measure- 1. Probably regulator fault, try another alternator.
ment over the battery. The nominal charging volt-
age over the battery should be approx. 27.8-
28.6V.
27
Repair instructions Group 30: Electrical system
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 99.0
Bar 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
28
Group 30: Electrical system Malfunctions
Malfunctions
29
Malfunctions Group 30: Electrical system
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 range
2 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 level
19 Received network data in error
20 Reserved for SAE assignment
21 Reserved for SAE assignment
22 Reserved for SAE assignment
23 Reserved for SAE assignment
24 Reserved for SAE assignment
25 Reserved for SAE assignment
26 Reserved for SAE assignment
27 Reserved for SAE assignment
28 Reserved for SAE assignment
29 Reserved for SAE assignment
30 Reserved for SAE assignment
31 Condition exist
30
Group 30: Electrical system Malfunctions
General advice
NOTE!
The following must be done before fault trac-
ing continues, to avoid changing functional
sensors:
If there is an active/inactive fault code. After an action with the connector
Remove the connector from the sensor. Check Put the connector* back. Check if the fault code
that there is no oxidation and that the connector becomes inactive.
pins are not damaged. Check faults that could be related to that specif-
ic sensor.
If there is a fault, please refer to the instructions
in chapter Fault tracing of cables and connec- If the fault remains, measure the cables and
tors. sensors to check them, as instructed.
*NOTE! No grease in the connector.
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 running.
31
Malfunctions Group 30: Electrical system
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 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 others 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 accordance with standard SAE
J1708.
32
Group 30: Electrical system Malfunctions
NOTE!
When resistance measurement is done, the engine
should be stopped and system voltage should be
cut off with the main switch.
All resistance measurement is done at +20C
(68F) and with a cold engine.
33
Diagnostic Trouble Codes Group 30: Electrical system
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. Preheat relay is im-
possible to turn off. Preheat fuse will
break.
34
Group 30: Electrical system Diagnostic Trouble Codes
Circuit description
In cold climate the intake air need too be preheated.
This is either done for GE engines by the preheater
which is located in the inlet manifoldor or for VE en-
gines by the glowplugs that are mounted in the cylin-
pre-heat relay derhead. The preheat function is activated/deactivated
by the engine control unit via the preheat relay. When
the preheat function is activated B25 alter 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
Suitable action:
1. Check cable harness and connectors between
EMS 2 and preheat relay.
Suitable action:
1. Check cable harness and connectors between
EMS 2 and preheat relay.
35
Diagnostic Trouble Codes Group 30: Electrical system
Suitable action:
1. Check the contact pressure in socket 25 in the
engine connector B.
2. Check cable harness and connectors between
EMS 2 and preheat relay.
Measurements
NOTE! If any of the measurements shows an abnor-
mal value, check the wiring to and from the engine
control unit and the preheat relay.
36
Group 30: Electrical system Diagnostic Trouble Codes
Fault indication
DCU: Engine warning in DCU display.
CIU: Flash code
Flash code
Electrical fault: 3.6
Value fault: 3.8
Symptom
None
Circuit description
The sensor is an active sensor, i.e. the sensor must
receive operating voltage. Pin B17 on the engine con-
splice trol unit provides pin 1 on the sensor with an operating
splice fuel pres- voltage of +5 Volt. Pin 4 on the sensor is connected to
sure
battery negative via pin B18 on the engine control unit.
The output signal from the pressure sensor, pin 2 on
engine
interface the sensor to pin B16 on the EMS 2, is a voltage sig-
nal that is proportional to the fuel pressure.
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.
37
Diagnostic Trouble Codes Group 30: Electrical system
Fault tracing
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 engine
connector B. Also check contact pressure in con-
nector at fuel pressure sensor.
2. Check cable harness and connectors between fuel
sensor and EMS 2.
3. Check function of fuel pressure sensor.
38
Group 30: Electrical system Diagnostic Trouble Codes
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 in
the engine connector B. Also check contact 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.
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 control
measuring the fuel pressure. (see workshop man-
ual)
7. Check fuel feed pump.
8. Change fuel pressure release valve. (see workshop
manual)
39
Diagnostic Trouble Codes Group 30: Electrical system
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.
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.
40
Group 30: Electrical system Diagnostic Trouble Codes
Signal 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.
41
Diagnostic Trouble Codes Group 30: Electrical system
Component specification
Working range: 0 7 bar = 0 700 kPa
Output voltage, V
42
Group 30: Electrical system Diagnostic Trouble Codes
Fault indication
DCU: Engine warning in DCU display
CIU: Flash code
Flash code
Electrical fault: 2.9
Value fault: 2.1
Symptom
None
water in
Circuit description
fuel
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.
splice
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 is
any water in the fuel, the resistance falls.
At a threshold resistance (water has been detected),
the monitors output signal (yellow cable) to the engine
control unit pin B8 will be pulled down to zero.
43
Diagnostic Trouble Codes Group 30: Electrical system
Fault tracing
Suitable action:
1. Empty the water trap.
2. Check function of water in fuel monitor.
FMI 3
Conditions for fault code:
The voltage signal on B8 is too high.
Possible reason:
The cable connected to B8 is short circuited to
battery voltage.
Suitable action:
1. Check cable harness and connectors between 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.
Suitable action:
1. Check cable harness and connectors between wa-
ter in fuel monitor and EMS 2.
44
Group 30: Electrical system Diagnostic Trouble Codes
Measurements
Supply cable:
NOTE! Turn ignition off.
Disconnect the connector from the monitor
Use multimeter 9812519 for voltage measurement
NOTE! Turn ignition on.
Negative 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.
45
Diagnostic Trouble Codes Group 30: Electrical system
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 parameter is activated.
46
Group 30: Electrical system Diagnostic Trouble Codes
Circuit description
The sensor is an active sensor, i.e. the sensor must
receive operating voltage. Pin B17 on the engine con-
oil pressure
splice trol unit (EMS 2) provides pin 1 on the sensor with an
splice operating voltage of +5 Volt. Pin 3 on the sensor is
connected to battery negative via pin B18 on the EMS
2.
The output signal from the pressure sensor, pin 2 on
the sensor to pin B11 on the EMS 2, is a voltage sig-
Note! Only TAD 650, 660, 750, 760 has an engine interface. On nal that is proportional to the oil pressure (after the oil
TAD 734 the wiring to the EMS 2 is the same but without any en- filters).
gine interface.
Fault tracing
Possible reason:
Too low engine oil level.
Blocked oil filter.
Oil leakage.
Faulty oil pressure sensor.
Suitable action:
1. Check engine oil level and quality of the oil.
2. Change engine oil and oil filter to prevent blocked
oil filter.
3. Check that no engine oil leakage occurs.
4. Check function of oil pressure sensor by control
measuring the engine oil pressure (see workshop
manual Group 21-26).
47
Diagnostic Trouble Codes Group 30: Electrical system
Possible reason:
Short circuit between signal cable and 5V supply
to oil pressure sensor.
Faulty sensor.
Suitable action:
1. Check cable harness and connectors between oil
pressure sensor and EMS 2.
2. Check function of oil pressure sensor.
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 pressure in socket 11 and 17 in
engine connector B. Also check contact pressure
in connector at oil pressure sensor.
2. Check cable harness and connectors between oil
pressure sensor and EMS 2.
3. Check function of oil pressure sensor.
48
Group 30: Electrical system Diagnostic Trouble Codes
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.
Remove the connector from the sensor.
Connect adapter cable 885675 between the sen-
sor and engine control unit.
Use multimeter 9812519 for voltage measurement
NOTE! Turn ignition on.
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.
49
Diagnostic Trouble Codes Group 30: Electrical system
Signal 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.
50
Group 30: Electrical system Diagnostic Trouble Codes
Component specification
Working range: 0 7 bar = 0 700 kPa
Supply voltage: 5,00 +/- 0,25 VDC
Output voltage, V
51
Diagnostic Trouble Codes Group 30: Electrical system
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 activated.
FMI 4, 5: Pressure set to 40 C.
52
Group 30: Electrical system Diagnostic Trouble Codes
Circuit description
The boost temperature sensor consists of a thermistor
splice which forms a closed circuit with an internal resistor in
the engine control unit (EMS 2), via the engine inter-
Boost air and face. The thermistor resistor changes in a non-linear
splice temperature
manner, depending on the boost temperature.
The EMS 2 provides the circuit with a reference volt-
engine age of +5 Volt. The EMS 2 measures the voltage drop
interface
Note! Only TAD 650, 660, 750, 760 has an engine interface. On
over the thermistor via pin A47 and pin A11 on the
TAD 734 the wiring to the EMS 2 is the same but without any en- EMS 2. Pin 1 on the sensor is connected to battery
gine interface. negative via pin A11 on the EMS 2.
When the boost air is cold, the thermistor resistance
is high and the EMS 2 senses a high voltage drop. As
the boost air warms up, the resistance in the ther-
mistor falls and the voltage drop across it falls.
Fault tracing
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.
53
Diagnostic Trouble Codes Group 30: Electrical system
Possible reason:
Short circuited sensor signal cable to battery neg-
ative.
Faulty sensor.
Suitable action:
1. Check cable harness and connectors between
boost temperature sensor and EMS 2.
2. Check function of boost temperature sensor.
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 7 in en-
gine connector A. Also check contact pressure in
connector at boost temperture sensor.
2. Check cable harness and connectors between
boost temperature sensor and EMS 2.
3. Check function of boost temperature sensor.
54
Group 30: Electrical system Diagnostic Trouble Codes
Measurements
NOTE! If any of the measurements shows an abnor-
mal value, check the wiring to and from the engine in-
terface.
Signal 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.
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.
55
Diagnostic Trouble Codes Group 30: Electrical system
56
Group 30: Electrical system Diagnostic Trouble Codes
57
Diagnostic Trouble Codes Group 30: Electrical system
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 set to atmospheric pressure
+ 30 kPa. Engine performance is derated.
58
Group 30: Electrical system Diagnostic Trouble Codes
Circuit description
The sensor is an active sensor, i.e. the sensor must
splice receive operating voltage. The boost pressure sensor
measures the absolute pressure, which is the sum of
boost air and
splice temperature the boost pressure and atmospheric pressure (300
kPa thus corresponds to a boost pressure of 200 kPa
when atmospheric pressure is 100 kPa).
engine Pin A7 on the engine control unit (EMS 2) provides pin
interface
3 on the sensor with an operating voltage of +5 Volt.
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-
Pin 1 on the sensor is connected to battery negative
gine interface. via pin A11 on the EMS 2. The output signal from the
pressure sensor, pin 4 on the sensor to pin A22 on the
EMS 2, is a voltage signal that is proportional to the
boost pressure.
Fault tracing
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 workshop
manual Group 21-26).
2. Check function of boost pressure sensor by con-
trol measuring boost pressure using a measuring
tap (see workshop manual Group 21-26).
3. Check that turbo compressor unit is in according
to the engine specification.
59
Diagnostic Trouble Codes Group 30: Electrical system
Possible reason:
Short circuited sensor signal cable to 5V voltage
or battery voltage.
Faulty sensor.
Suitable action:
1. Check cable harness and connectors between
boost pressure sensor and EMS 2.
2. Check function of boost pressure sensor.
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 and 11 in
engine connector A. Also check contact pressure
in connector at boost pressure sensor.
2. Check cable harness and connectors between
boost pressure sensor and EMS 2.
3. Check function of boost pressure sensor.
60
Group 30: Electrical system Diagnostic Trouble Codes
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.
Remove the connector from the sensor. Connect
adapter cable 885675 between the sensor and en-
gine control unit.
Use multimeter 9812519 for voltage measurement
Turn ignition on.
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.
61
Diagnostic Trouble Codes Group 30: Electrical system
Signal 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.
62
Checking boost 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 measure-
ment.
Turn ignition on.
Component specification
Working range: 0,5 4,0 bar = 50 400 kPa
Output voltage, V
63
Diagnostic Trouble Codes Group 30: Electrical system
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 control unit.
64
Group 30: Electrical system Diagnostic Trouble Codes
Fault tracing
FMI 2, 3, 4
Conditions for fault code:
Suitable action:
1. Replace the engine control unit (EMS 2).
65
Diagnostic Trouble Codes Group 30: Electrical system
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
66
Group 30: Electrical system Diagnostic Trouble Codes
Circuit description
skall vara 18 ej 10
The coolant temperature sensor consists of a ther-
mistor which forms a closed circuit with an internal re-
splice sistor in the engine control unit (EMS 2) via the en-
coolant tem-
perture gine interface. The thermistor resistor changes in a
non-linear manner, depending on the coolant tempera-
engine
interface ture. The EMS 2 provides the circuit with a reference
voltage of +5 Volt. The EMS 2 measures the voltage
Note! Only TAD 650, 660, 750, 760 has an engine interface. On drop over the thermistor via pin B27 and pin B18 on
TAD 734 the wiring to the EMS 2 is the same but without any en- the EMS 2. Pin 1 on the sensor is connected to bat-
gine interface. tery negative via pin B18 on the EMS 2. When the
coolant is cold, the thermistor resistance is high and
the EMS 2 senses a high voltage drop. As the coolant
warms up, the resistance in the thermistor falls and
the voltage drop across it falls.
Fault tracing
FMI 0: Coolant 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 outside of the radiator for dust and dirt.
3. Check drive belt adjustment.
4. Bleed coolant water system.
5. If low coolant level check coolant water system for
leakage by a pressure test.
6. Check coolant pressure valve in the coolant cup
or try with another coolant cup.
7. Check coolant water thermostat or change cool-
ant water thermostat.
8. Check function of coolant temperature sensor.
9. Clean cooling water system.
67
Diagnostic Trouble Codes Group 30: Electrical system
Possible reason:
Short circuit between both cables to the coolant
temperature sensor.
Faulty sensor.
Suitable action:
1. Check cable harness and all connectors between
coolant temperature sensor and EMS 2.
2. Check function of coolant temperature sensor.
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. Check also contact pressure
in connector at coolant temperature sensor.
2. Check cable harness and all connectors between
coolant temperature sensor and EMS 2.
3. Check function of coolant temperature sensor.
68
Group 30: Electrical system Diagnostic Trouble Codes
Measurements
NOTE! If any of the measurements shows an abnor-
mal value, check the wiring to and from the engine in-
terface.
Signal 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.
NOTE! Turn ignition on.
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.
69
Diagnostic Trouble Codes Group 30: Electrical system
70
Group 30: Electrical system Diagnostic Trouble Codes
71
Diagnostic Trouble Codes Group 30: Electrical system
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.
72
Group 30: Electrical system Diagnostic Trouble Codes
Circuit description
The coolant level in the engine is monitored by a level
switch. Pin B23 on the engine control unit (EMS 2)
provides pin 1 on the level switch with a voltage. Pin 2
on the level switch is connected to battery negative via
coolant level pin B10 on the engine control unit.
The level switch has two states: On/Off.
The level switch consists of two sections, the actual
switch and a magnetic float which is built into the ex-
pansion tank. The switch senses the position of the
magnetic float. When the coolant level falls, the float
operates the switch and a closed circuit is formed.
Fault tracing
Possible reason:
Short circuit to battery voltage on pin B23.
Suitable action:
1. Check cable harness and connectors between
coolant level monitor and EMS2.
73
Diagnostic Trouble Codes Group 30: Electrical system
Measurements
Supply cable:
NOTE! Turn ignition off.
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 for voltage measurement
NOTE! Turn the ignition on.
Negative cable:
NOTE! Cut the current with the main switch.
Disconnect the connector from the level switch.
The point of con- Connect adapter cable 885675 to the cable har-
nection for battery ness connector to the engine control unit.
negative on the en-
gine Use multimeter 9812519 to do resistance mea-
surement against the engine control unit.
74
Group 30: Electrical system Diagnostic Trouble Codes
75
Diagnostic Trouble Codes Group 30: Electrical system
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.
76
Group 30: Electrical system Diagnostic Trouble Codes
Fault tracing
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.
77
Diagnostic Trouble Codes Group 30: Electrical system
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 home with
pressure release valve opened. An esti-
mated rail pressure with depending to
fuel quantity will be used.
78
Group 30: Electrical system Diagnostic Trouble Codes
Circuit description
The sensor is an active sensor, i.e. the sensor must
receive operating voltage. Pin A7 on the engine control
unit (EMS 2) provides pin 3 on the sensor with an op-
rail pressure erating voltage of +5 Volt. Pin 1 on the sensor is con-
nected to battery negative via pin A11 on the EMS 2.
The output signal from the pressure sensor, pin 2 on
engine the sensor to pin A19 on the EMS 2, is a voltage sig-
interface nal that is proportional to the rail pressure.
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.
Fault tracing
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 rail pressure sensor.
Suitable reason:
1. Check function of rail pressure sensor.
79
Diagnostic Trouble Codes Group 30: Electrical system
Possible reason:
Short circuited sensor signal cable to battery neg-
ative.
Faulty rail pressure sensor.
Suitable action:
1. Check cable harness and connectors between rail
pressure sensor and EMS 2.
2. Check function of rail pressure sensor.
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.
Suitable action:
1. Check contact pressure in socket 7, 11 and 19 in
engine connector A. Also check contact pressure
in connector at fuel pressure sensor.
2. Check cable harness and connectors between rail
pressure sensor and EMS 2.
2. Check function of rail pressure sensor.
80
Group 30: Electrical system Diagnostic Trouble Codes
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.
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.
81
Diagnostic Trouble Codes Group 30: Electrical system
Signal 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.
82
Group 30: Electrical system Diagnostic Trouble Codes
Component specification
Working range: 0 1800 bar = 0 180 MPa
Supply voltage: 5.00 +/- 0.25 VDC
83
Diagnostic Trouble Codes Group 30: Electrical system
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.
84
Group 30: Electrical system Diagnostic Trouble Codes
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 engine can not be started.
85
Diagnostic Trouble Codes Group 30: Electrical system
Fault tracing
FMI 3 Abnormally high voltage or short
circuit to higher voltage
Possible reason:
Suitable action:
1. Check that start switch is connected correctly.
2. Check cable harness and connectors between
CIU and start switch.
3. Check function of start switch.
Suitable action:
1. Check that start switch is connected correctly.
2. Check contact pressure in socket 35 in the CIU
connector.
3. Check cable harness and connectors between
CIU and start switch.
4. Check function of start switch.
86
Group 30: Electrical system Diagnostic Trouble Codes
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 using AUX stop.
FMI5: Engine cant be stopped.
87
Diagnostic Trouble Codes Group 30: Electrical system
Fault tracing
Suitable action:
1. Check that the stop button isnt stucked.
2. Check that stop button is connected correctly.
3. Check cable harness and connectors at aux stop
button at EMS / stop button at CIU.
4. Check function of aux stop button at EMS / stop
button at CIU.
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.
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.
88
Group 30: Electrical system Diagnostic Trouble Codes
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 on.
FMI 7: May damage turbine, increased
power and emissions.
89
Diagnostic Trouble Codes Group 30: Electrical system
Circuit description
Internal exhaust gas recirculation, IEGR, is like the
name says used for recirculation of exhaust gases.
This for lowering the emissions from the engine. The
IEGR valve is a 2-way solenoid valve controlled by
engine the engine control unit. The IEGR solenoid controls a
interface
oil pressure that effects a control valve which activate
the exhaust gas recirculation function. The solenoid is
activated when pin B30 on the EMS 2 changes its po-
tential.
Fault tracing
Suitable action:
1. Check cable harness and connectors between
EMS 2 and IEGR.
Suitable action:
1. Check cable harness and connectors between
EMS 2 and IEGR.
90
Group 30: Electrical system Diagnostic Trouble Codes
Suitable action:
1. Check cable harness and connectors between
EMS 2 and IEGR.
2. Check IEGR coil.
Suitable 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.
91
Diagnostic Trouble Codes Group 30: Electrical system
92
Group 30: Electrical system Diagnostic Trouble Codes
Fault indication
DCU: Engine warning in DCU display.
CIU: None
Flash code
Electrical fault: 8.4
Value fault: None
Symptom
None.
93
Diagnostic Trouble Codes Group 30: Electrical system
Circuit description
The temperature sensor is installed inside of the EMS
2 unit.
Fault tracing
FMI 0
Fault condition:
The temperature inside the engine control unit is too
high.
Possible reason:
High surrounding 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.
Suitable action:
1. Change EMS 2 unit.
Suitable action:
1. Change EMS 2 unit.
94
Group 30: Electrical system Diagnostic Trouble Codes
Fault indication
DCU Engine warning in DCU display.
CIU Flashcode
Flash code
Electrical fault: None
95
Diagnostic Trouble Codes Group 30: Electrical system
Fault tracing
NOTE! If the control panel ONLY communicates on
the J1939 communication and NOT the redundancy of
J1587 for start, stop and throttle this fault code is ac-
tive in the VODIA 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 is programmed for correct
engine type.
96
Group 30: Electrical system Diagnostic Trouble Codes
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
first and then pressed down again the engine can be
forced to run using the idle contact.
97
Diagnostic Trouble Codes Group 30: Electrical system
Fault tracing
NOTE! If the control panel ONLY communicates on
the J1939 communication and NOT the redundancy of
J1587 for start, stop and throttle this fault code is ac-
tive in the VODIA and that is normal.
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.
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.
98
Group 30: Electrical system Diagnostic Trouble Codes
FMI 9
Fault condition:
EMS2 gets no throttle signal on the J1939 bus from
the CIU.
Suitable action:
1. Check that the throttle potentiometer is connected
correctly.
2. Check cable harness and connectors between
CIU and CIU throttle potentiometer.
3. Check function of throttle potentiometer.
4. Check contact pressure in socket 2, 3 and 30 in
CIU connector.
99
Diagnostic Trouble Codes Group 30: Electrical 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. Limp home
on rest of injectors.
100
Group 30: Electrical system Diagnostic Trouble Codes
Circuit description
The electronic injectors used on the engine has an
electronically controlled solenoid. The solenoid is con-
splice
trolled by the engine control unit.
The injectors receive voltage from pin A59 orA 60 on
the engine control unit. To activate an injector solenoid
the engine control unit grounds the current injector.
splice
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.
Fault tracing
NOTE! Identify which injector by the SID number.
Possible reason:
Short circuit to battery voltage on the pin on the
respective injectors 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 cable harness and connectors between in-
jectors and engine control unit (EMS 2).
101
Diagnostic Trouble Codes Group 30: Electrical system
Possible reason:
Short circuit to battery negative on the pin on the
respective injectors high voltage side. (EMS 2
pin: 59 and 60)
Short circuit to battery negative in high voltage in-
jector wire.
Suitable action:
1. Check cable harness and connectors between in-
jectors and engine control unit (EMS 2).
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 injectors high voltage side. (EMS 2
pin: 59 and 60)
Short circuit to battery negative on the pin on the
respective injectors low voltage side. (EMS 2 pin:
56, 52, 48 and 44, 40, 36)
Suitable action:
1. Check contact pressure in socket 36, 40, 44 ,52,
56, 59 and 60 in engine connector A.
2. Check cable harness and connectors between in-
jectors and engine control unit (EMS 2).
102
Group 30: Electrical system Diagnostic Trouble Codes
FMI 7
Conditions for fault code:
Injector activated and cylinder balancing above limit.
If a fault code is set when the engine has an unsym-
metrical load it can not be rectified. At idle speed the
engine control unit is trying to compensate for uneven
running by adding more or less fuel to the injectors,
cylinder balancing. If the engine load is too unsymmet-
rical 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.
Possible reason:
Intermittent fault.
Suitable action:
1. Check cables harness and connectors between
injector and engine control unit.
103
Diagnostic Trouble Codes Group 30: Electrical system
FMI 14
Conditions for fault code:
Low or high flow through injector.
Possible reason:
Faulty injector: leakage in spill valve, increased
nozzle hole.
Suitable action:
1. Change only the faulty injector.
Measurements
NOTE! If any of the measurements shows an abnor-
mal value, check the wiring to and from the engine in-
terface.
104
Group 30: Electrical system Diagnostic Trouble Codes
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.
105
Diagnostic Trouble Codes Group 30: Electrical system
Circuit description
The camshaft sensor is an inductive sensor. When
the camshaft rotates impulses are created in the sen-
speed sensor, sor via a tooth wheel installed on the camshaft. The
camshaft tooth wheel has 7 teeth, one for each cylinder + one
to determine when cylinder one is to be injected. The
engine
impulses create a pulse signal in the sensor that the
interface
engine control unit (EMS 2) uses to calculate when a
cylinder is in turn for injection.
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.
Fault tracing
Possible reason:
Polarity fault. The cables to the cam sensor is
shifted.
Intermittent fault.
Incorrectly mounted cam sensor.
Suitable action:
1. Check cable harness and connectors between
cam sensor and EMS 2.
2. Check that the cam sensor is connected as in the
circuit description.
3. Check contact pressure in socket 45 and 46 in
engine connector A.
4. Check function of cam sensor.
106
Group 30: Electrical system Diagnostic Trouble Codes
Possible reason:
Incorrectly mounted cam sensor.
An open circuit in any or both of the cables to the
cam sensor.
Short circuit between cables to cam sensor.
Faulty cam sensor.
Suitable action:
1. Check installation of cam speed sensor.
2. Check cable harness and connectors between
cam sensor and EMS 2.
3. Check contact pressure in socket 45 and 46 in
engine connector A.
4. Check function of cam sensor.
Possible reason:
Incorrectly mounted speed sensor.
Electrical interference in the speed signal.
Suitable action:
1. Check wiring between cam sensor and EMS 2.
2. Check contact pressure in socket 45 and 46 in
engine connector A.
3. Check installation of cam sensor.
4. Attempt to localize the source of interference.
5. Check function of cam sensor.
107
Diagnostic Trouble Codes Group 30: Electrical system
Measurements
NOTE! If any of the measurements shows an abnor-
mal value, check the wiring to and from the engine in-
terface.
108
Group 30: Electrical system Diagnostic Trouble Codes
109
Diagnostic Trouble Codes Group 30: Electrical system
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
sensor.
110
Group 30: Electrical system Diagnostic Trouble Codes
Circuit description
The speed sensor is an inductive sensor. When the
crankshaft rotates impulses are created in the sensor
via a tooth wheel on or behind the torsion damper. The
speed sensor, impulses create a pulse signal in the sensor that the
crankshaft engine control unit (EMS 2) uses to calculate the
engine crankshaft rpm.
interface
The tooth wheel has a tooth free gap for the EMS 2 to
recognize the position of the crankshaft.
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.
Fault tracing
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. Check function of speed sensor.
111
Diagnostic Trouble Codes Group 30: Electrical system
Possible reason:
Open circuit in any or both of cables to the speed
sensor.
Incorrectly mounted speed sensor.
Faulty speed sensor.
Suitable action:
1. Check cable harness and connectors between
speed sensor and EMS 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.
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. Check contact pressure in socket 37 and 38 in
engine connector A.
3. Check installation of speed sensor.
4. Attempt to localize the source of interference.
5. Check and clean the speed sensor.
112
Group 30: Electrical system Diagnostic Trouble Codes
Measurements
NOTE! If any of the measurements shows an abnor-
mal value, check the wiring to and from the engine in-
terface.
113
Diagnostic Trouble Codes Group 30: Electrical system
114
Group 30: Electrical system Diagnostic Trouble Codes
Fault indication
DCU: Engine warning in DCU display.
CIU: None
Flash code
Electrical fault: 4.6
Value fault: None
Symptom
Start motor does not engage.
Circuit description
The starter relay is located on the starter motor. When
ignition is on, the starter relay recives battery voltage
from B57 and B60. B29 is not activated. When the
starter
relay
start button is activated B29 alter its potential and the
relay activates.
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.
115
Diagnostic Trouble Codes Group 30: Electrical system
Fault tracing
FMI 3
Conditions for fault code:
Short circuit too battery voltage.
Possible reason:
Short circuit in starter relay cable.
Faulty starter relay.
Suitable action:
1. Check cable harness and connections between
starter relay and EMS 2.
2. Check function of starter relay.
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 between
starter relay and EMS 2.
2. Check function of starter relay.
116
Group 30: Electrical system Diagnostic Trouble Codes
FMI 5
Conditions for fault code:
Open circuit.
Possible reason:
An open circuit in starter relay cable.
Faulty starter relay.
Suitable action:
1. Check cable harness and connections between
starter relay and EMS 2.
2. Check contact pressure in socket B29 in engine
connector.
3. Check function of starter relay.
Measurements
Checking starter relay coil
117
Diagnostic Trouble Codes Group 30: Electrical system
Fault indication
DCU: Engine warning in DCU display
CIU: None
Flash code
Electrical fault: 8.3
Value fault: None
Symptom
All FMI: Full fuel flow delivery. Limp home with
pressure release valve opened.
FMI 5, 13: Possible stall of engine.
118
Group 30: Electrical system Diagnostic Trouble Codes
Component description
A magnetically controlled proportional valve (MPROP)
controls the fuel pressure (rail pressure) to ensure that
the correct fuel pressure is retained despite varying
Magnetic proprotional engine speed and loading. Signal from engine control
valve (MPROP)
unit is a PWM signal (pulse width modulated signal).
When the current through the valve is changed, this
engine
affects the fuel flow, which results in changed rail
interface
pressure. The rail pressure sensor senses the pres-
Note! Only TAD 650, 660, 750, 760 has an engine interface. On sure and converts the pressure signal to a voltage
TAD 734 the wiring to the EMS 2 is the same but without any en- which is registered by the engine control unit. If the
gine interface.
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
Suitable action:
1. Check cable harness and connectors between
EMS 2 and MPROP.
Suitable action:
1. Check cable harness and connectors between
EMS 2 and MPROP.
119
Diagnostic Trouble Codes Group 30: Electrical system
Suitable action:
1. Check contact pressure in socket 12 and 16 in
engine connector A. Also check contact pressure
in connector at MPROP.
2. Check cable harness and connectors between
EMS 2 and MPROP.
Suitable action:
1. Check contact pressure in socket 12 and 16 in
engine connector A. Also check contact pressure
in connector at MPROP.
2. Check cable harness and connectors between
EMS 2 and MPROP
FMI 13
Possible reason:
Short circuit to battery negative in MPROP nega-
tive cable, pin 2 on MPROP.
Suitable action:
1. Check cable harness and connectors between
EMS 2 and MPROP.
120
Group 30: Electrical system Diagnostic Trouble Codes
Measurements
NOTE! If any of the measurements shows an abnor-
mal value, check the wiring to and from the engine in-
terface.
121
Diagnostic Trouble Codes Group 30: Electrical system
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 start problems in cold climate.
122
Group 30: Electrical system Diagnostic Trouble Codes
Fault tracing
Suitable action:
1. Check cable harness and connectors to heating
element.
2. Check function of preheat relay.
3. Change heating element.
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 socket 7 in engine con-
nector B.
2. Check cable harness and connections to heating
element.
3. Change heating element.
123
Diagnostic Trouble Codes Group 30: Electrical system
Fault indication
DCU: Engine warning in DCU display.
CIU: None
Flash code
Electrical fault: 9.3
Value fault: None
Symptom
None
124
Group 30: Electrical system Diagnostic Trouble Codes
Fault tracing
FMI 3 Abnormally high voltage or short
circuit to higher voltage
Conditions for fault code:
The voltage exceeds the normal value or is short cir-
cuited to higher voltage.
Possible reason:
Short circuit between 5V supply voltage 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)
Suitable action:
1. Check the sensor supply cables to oil pressure
sensor.
2. Check the sensor supply cables to fuel pressure
sensor.
125
Diagnostic Trouble Codes Group 30: Electrical system
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.
126
Group 30: Electrical system Diagnostic Trouble Codes
Cable description
CAN H-datalink to engine
B51
CAN L-datalink to engine
B55
Power supply
Power supply input
Ignition
A58
Stop
A27
J1708A-datalink to engine
A34
J1708B-datalink to engine
A33
Fault tracing
Possible reason:
CAN H and CAN L short circuited 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.
127
Diagnostic Trouble Codes Group 30: Electrical system
Measurements
Checking the CAN bus cable. The resistance of the
CAN bus termination resistors, one 120 resistor in
the ECU and one 120 resistor in the cable harness,
are measured.
or
128
Group 30: Electrical system Diagnostic Trouble Codes
Fault indication
DCU: Engine warning in DCU display.
CIU: None
Flash code
Electrical fault: 9.3
Value fault: None
Symptom
None
129
Diagnostic Trouble Codes Group 30: Electrical system
Fault tracing
FMI 3 Abnormally high voltage or short
circuit to higher voltage
Conditions for fault code:
The voltage exceeds the normal value or is short cir-
cuited to higher voltage.
Possible reason:
Short circuit between 5V supply voltage 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)
Suitable action:
1. Check the sensor supply cables to boost pressure
sensor.
2. Check the sensor supply cables to rail pressure
sensor.
130
Group 30: Electrical system Diagnostic Trouble Codes
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 engine control unit.
2. Change the engine control unit.
131
Diagnostic Trouble Codes Group 30: Electrical system
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 control unit.
132
Group 30: Electrical system Diagnostic Trouble Codes
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 limita-
tion (1100 rpm). Fuel pressure limita-
tion (800 bar). Engine torque reduc-
tion.
FMI 4: Engine derated: engine speed limita-
tion (1100 rpm). Fuel pressure limita-
tion (800 bar). Engine torque reduc-
tion. Engine shut off or difficult to
start.
133
Diagnostic Trouble Codes Group 30: Electrical system
Fault tracing
FMI 0
Conditions for fault code:
Rail pressure controller integral part too low.
Possible reason:
MPROP stuck open due to mechanical fault or an
open circuit in MPROP electrical wiring.
Faulty rail pressure sensor.
An injector does not open.
Suitable action:
1. Check contact pressure in socket 12 and 16 in en-
gine connector A.
2. Check MPROP cables and connectors.
3. Check function of rail pressure sensor.
4. Change MPROP valve.
5. Check if an injector 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 leakage (high pressure pipes,
suction pipes, return pipes).
2. Check function of rail pressure sensor (see MID
128, PID 164).
3. Change the rail pressure release valve.
4. Check MPROP cables and connectors.
5. Change MPROP valve.
6. Check if an injector is faulty.
7. Check both high pressure pumps (see workshop
manual Group 21-26).
134
Group 30: Electrical system Diagnostic Trouble Codes
FMI 4
Conditions for fault code:
Low rail pressure
Possible reason:
Low fuel level.
Air gets into the fuel system.
High pressure leakage.
Low pressure leakage.
Blocked fuel filter, pre- and fine filter.
Faulty rail pressure sensor.
MPROP closed or partly closed or out of 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 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 21-26).
FMI 7
Conditions for fault code:
Cylinder balancing exceeding upper threshold. Rail
pressure controller integral part too big.
Possible reason:
High pressure pipes rail to injector leakage, see
SID1-6 (FMI 7) for info which injector.
Suitable action:
1. Check for leakage in the high pressure system.
135
Diagnostic Trouble Codes Group 30: Electrical system
FMI 12
Conditions for fault code:
Rail pressure too low. Rail pressure nominal value de-
viates positive from set point value.
Possible reason:
Low fuel level.
Air gets into the fuel system.
High pressure leakage.
Low pressure leakage.
Blocked fuel filter, pre- and fine filter.
Faulty rail pressure sensor.
MPROP closed or partly closed or out of 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 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.
136
Group 30: Electrical system Diagnostic Trouble Codes
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.
137
Diagnostic Trouble Codes Group 30: Electrical system
Circuit description
The task of the pressure limiting valve (safety valve)
is to protect the system from excess pressure. The
valve opens and reduces the fuel pressure (rail pres-
sure) by releasing fuel to the return pipe as neces-
sary. The valve is a two-stage valve. Stage one
opens at about 190 MPa (1900 bar / 27557 psi) 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:
Rail pressure controller out of range.
Faulty rail pressure release valve.
Suitable action:
1. Check function of rail pressure sensor.
2. Change the rail pressure release valve.
138
Group 30: Electrical system Diagnostic Trouble Codes
FMI 7
Conditions for fault code:
Rail pressure release valve stuck close.
Possible reason:
An open circuit in one or both cables from EMS 2
to MPROP.
Short circuit to battery negative in MPROP posi-
tive wire, pin 1 on MPROP.
Rail pressure release valve stuck close.
Suitable action:
1. Check contact pressure in socket 12 and 16 in
engine connector A. Also check contact pressure
in connector at MPROP.
2. Check cable harness and connectors between
EMS 2 and MPROP.
3. Change the 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 close or out of char-
acteristic.
Suitable action:
1. Check function of rail pressure sensor.
2. Change the rail pressure release valve.
139
Diagnostic Trouble Codes Group 30: Electrical system
FMI 14
Conditions for fault code:
Rail pressure release valve stuck open.
Possible reason:
Blocked fuel return line.
An open circuit in one or both cables from EMS 2
to MPROP.
Short circuit to battery negative in MPROP 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.
140
Group 30: Electrical system Diagnostic Trouble Codes
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
B51
CAN L-datalink to engine
B55
Power supply
Power supply input
Ignition
A58
Stop
A27
J1708A-datalink to engine
A34
J1708B-datalink to engine
A33
141
Diagnostic Trouble Codes Group 30: Electrical system
Fault tracing
FMI 9
Conditions for fault code:
No communication with the engine control unit.
Possible reason:
An open circuit in CAN H or CAN L or both CAN
links between EMS 2 and DCU/CIU.
An open circuit in Power supply 0V cable between
EMS 2 and DCU/CIU.
An open circuit in Power supply input cable 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, via the engine connector.
142
Group 30: Electrical system Diagnostic Trouble Codes
Measurements
Checking the CAN bus cable. The resistance of the
CAN bus termination resistors, one 120 resistor in
the ECU and one 120 resistor in the cable harness,
are measured.
or
143
Engine protection Group 30: Electrical system
Engine protection
TAD 650, 660, 750, 760 VE
Torque, Nm
Engine protection
Engine protection
TAD 734 GE
High oil
temperature (C) 125 135 >135
Low coolant
level - switch switch
300
250
Oil pressure kpa
200
150 Oil pressure limit
100
50
0
0 500 1000 1500 2000 2500
Engine speed
1. Connector (X17)
2. Start relay, supply
146
3. Internal EGR, supply
4. Internal EGR
5. Start relay
6. Coolant temperature
7. Coolant temperature, ground
Wiring diagram
1. Conector (x17)
2. Start relay, supply
3. Internal EGR, supply
4. Internal EGR
5. Start relay
6. Coolant temperature
7. Coolant temperature, ground
8. Oil pressure, ground
9. Fuel pressure, ground
10. Fuel pressure, supply
11. Oil pressure, supply
12. Fuel pressure
13. Oil pressure
14. Boost pressure/temperature, ground
15. Rail pressure, ground
16. Boost 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 sensor, crankshaft
34. Speed sensor, camshaft
Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
147
Wiring diagram Group 30: Electrical system
148
Group 30: Electrical system Wiring diagram
DCU
Cable colours
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
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)
149
Wiring diagram Group 30: Electrical system
Cable colors
CIU 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
150
Group 30: Electrical system Technical data
Technical data
151
Technical data Group 30: Electrical system
Alternator
Voltage ........................................................................................ 28V
Connector .................................................................................... 2-pin
Capacity ...................................................................................... 80 A at 28V
Starter motor
Voltage ........................................................................................ 24 V
Connector .................................................................................... 1 pol
Capacity ...................................................................................... 5.5 kW
152
Index
MID 128 (engine control unit EMS):
SPN Flashcode PID PPID SID PSID FMI Please refer
Electrical fault/ to page:
value fault
Ambient air pressure 108 -/- 108 2, 3, 4 64
Battery voltage 158 -/3.9 (EMS) 158 1 76
-/6.9 (CIU)
Boost pressure 106 3.4/3.5 106 0, 3, 5 58
Boost temperature 105 3.2/6.2 105 0, 4, 5 52
Group 30: Electrical system
153
Index
MID 128 (engine control unit EMS):
154
Index
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Signed: ..............................................................................
AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Gteborg
Sweden
7747632 English 032007