Volvo TAD650VE Workshop Manual
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Volvo TAD650VE Workshop Manual

Industrial engines
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Workshop Manual
I
Group 30
4(0)
TAD650VE, TAD660VE,
TAD734GE, TAD750VE, TAD760VE

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Summary of Contents for Volvo TAD650VE

  • Page 1 Workshop Manual Group 30 4(0) TAD650VE, TAD660VE, TAD734GE, TAD750VE, TAD760VE...

  • Page 3: Table Of Contents

    Group 30 Electrical system Industrial Engines TAD734GE, TAD650VE, TAD660VE, TAD750VE, TAD760VE Contents Sensor, common rail pressure (fuel) ....16 Safety rules ............3 Sensor, fuel pressure ......... 16 General information ..........4 Magnetically controlled proportional valve (MPROP) ............17 About this Workshop Manual ....... 4 Water in fuel switch, secondary fuel filter ..
  • Page 4 Communication fault J 1939 ......126 MID 128, SID 232 5V sensor supply 1 ........... 129 MID 128, SID 240 Program memory ..........131 © 2007 AB VOLVO PENTA We reserve the right to make modifications without prior notice. Printed on environmentally compatible paper.

  • Page 5: Safety Rules

    (crane etc.). This workshop manual contains technical data, de- scriptions and repair instructions for the Volvo Penta The engine must not be run in areas where ex- products or product versions noted in the table of con- plosive material or any gases are stored.

  • Page 6: General Information

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

  • Page 7: Repair Instructions

    Volvo Penta Special Tools available assume that these tools are used when carrying out the repair. Volvo Penta Special Tools have been de- veloped to ensure the most safe and rational working methods possible. It is therefore the responsibility of...

  • Page 8: Our Common Responsibility

    If lubricants, locking fluids or sealants are needed on a Volvo Penta Original Spares are used for the engine. fastener, the type of preparation to be used will be not- The stated service intervals in the Maintenance ed in the job description and in “Tightening Torques”.

  • Page 9: Special Tools

    Special tools Group 30: Electrical system Special tools 3838620 3838621 3838622 9812519 3838619 885675 9998482 9999324 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...

  • Page 10: Ems 2 - "Engine Management System

    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.

  • Page 11: Ciu - Control Interface Unit

    Group 30: Electrical system EMS 2 - “Engine Management System” CIU - Control Interface Unit The CIU is a “translator” between the CAN bus and the customer’s own control panel. This unit has two serial communication links, one fast and one slow. The fast one is a CAN link that features a bus speed of 250 Kbit/s.

  • Page 12: Fuel Control

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

  • Page 13: Component Location

    Group 30: Electrical system Component location Component location TAD 650, 660, 750, 760 VE NOTE! Location can differ, depending on engine model. 1. Speed sensor, camshaft 2. Connection, EMS 2 3. Solenoid controlled proportional valve, high pres- sure pump – fuel (MPROP) 4.

  • Page 14: Tad 734 Ge

    Component description Group 30: Electrical system Component location TAD 734 GE 1. Solenoid controlled proportional valve, high pressure pump – fuel (MPROP) 2. Coolant temperature sensor 3. Water in fuel switch(mounted on primary fuel filter). 4. Boost pressure and temperature sensor 5.

  • Page 15: Component Description

    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.

  • Page 16: Injectors

    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...

  • Page 17: Sensor, Boost Pressure/ Boost Temperature

    Group 30: Electrical system Component description Sensor, boost pressure / boost temperature The boost pressure and the boost temperature are measured by a combined sensor located on the inlet manifold on the left of the engine. The sensor is supplied by a 5 Volt reference voltage from the engine control module.

  • Page 18: Coolant Temperature Sensor

    Component description Group 30: Electrical system Coolant temperature sensor The sensor is located on the cylinder head, at the rear end of the engine. The sensor senses the engine coolant temperature and sends the information to the engine control unit. The sensor consists of a non-linear resistor, whose re- sistance varies with coolant temperature.

  • Page 19: Magnetically Controlled Proportional Valve (Mprop)

    Group 30: Electrical system Component description Magnetically controlled propor- tional valve (MPROP) A magnetically controlled proportional valve (MPROP) controls the high pressure pump to ensure that the correct fuel pressure (rail pressure) is retained despite varying engine speed and loading. The input signal to the valve is a PWM signal whose pulse width is controlled by the engine control module.

  • Page 20: Preheater

    Component description Group 30: Electrical system Preheater with preheater relay The preheater is located in the inlet manifold at the left side of the engine. The preheat relay is located at the engines left side beneath the preheater. Engine control unit, EMS 2 The engine control unit checks and controls the injec- tors, to ensure that the correct volume of fuel is inject- ed into each cylinder at the right time.

  • Page 21: Repair Instructions

    Group 30: Electrical system Repair instructions Repair instructions General advice on working with EMS engines The following advice must be followed to avoid damage to the engine control unit and other elec- tronics. IMPORTANT! The system must be disconnect- ed from system voltage (by cutting the current with the main switch) and the starter key(s) must be in the 0 position when the engine control module connectors are disconnected or connect-...

  • Page 22: Electric Welding

    Repair instructions Group 30: Electrical system Electric welding 1. NOTE! Cut the current with the main switch. IMPORTANT! The system must be disconnect- ed from system voltage when the engine control module connectors are disconnected or con- nected. 2. Undo the two connectors from the engine control unit before any electric welding starts.

  • Page 23: Changing The Engine Control Unit

    Group 30: Electrical system Repair instructions Changing the engine control unit 1. NOTE! Cut the current with the main switch. IMPORTANT! The system must be disconnect- ed from system voltage when the engine control module connectors are disconnected or con- nected*.

  • Page 24: Reprogramming A Control Unit

    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 Network’s web site: 4. Follow the instructions under “Download soft- www.vppn.com ware”.

  • Page 25: Programming An Empty Control Unit

    “Programming a control unit”. If the part numbers do not coincide – proceed as possible: 1. Have both part numbers available. 2. Log in to Volvo Penta Network’s web site: www.vppn.com 3. Choose “VODIA” in the left-hand menu.

  • Page 26: Fault Tracing Of Cables And Connectors

    Repair instructions Group 30: Electrical system Contact problems Fault tracing of cables and Intermittent contact or temporary recurring faults can connectors be difficult to fault trace, and are frequently caused by oxidation, vibration or poorly terminated cables. Special tools: 9812519, 999 8482 Wear can also cause faults.
  • Page 27 Group 30: Electrical system Repair instructions Joining electrical cables for connectors Special tools: 9808648, 999 9324 Repair kit: 107 8054 Disconnect the connector from the engine control unit or from the power supply unit, please refer to ”Control unit, changing”. Undo the connector, to gain access to the cable lead- ing to the pin which is to be changed.

  • Page 28: Checking The Starter Motor Voltage

    Repair instructions Group 30: Electrical system 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. Install the cables with insulation and tie wraps in the connector, in the reverse order to disassembly.

  • Page 29: Checking The Charging System

    Group 30: Electrical system Repair instructions Fault tracing charging system Checking the charging system Battery Special tools: 9812519 1. Check that all connectors at the battery is correct assembled. Generally about alternators: 2. Check the conditions of the cables to the battery. The voltage output from an alternator must be limited 3.

  • Page 30: Rail Pressure Measurement

    Repair instructions Group 30: Electrical system Rail pressure measurement This measurement is used for measuring the rail pres- sure. For example if the engine doesn’t start this mea- surement can show the rail pressure while the engine is cranking. If it is air in the system the rail pressure could be too low for the engine control unit to activate injection.

  • Page 31: Malfunctions

    MID - Message Identification Description: • PSID - Proprietary SID: The MID consists of a number which designates The same as the SID, but this is a Volvo-specific the control unit that sent the fault code message. component. (e.g. the engine control unit).

  • Page 32: Fmi Table Sae Standard

    Malfunctions Group 30: Electrical system FMI table SAE standard Display text SAE text “Value too high” Valid data, but above the normal working range “Value too low” Valid data, but below the normal working range “Faulty data” Intermittent or faulty data “Electrical fault”...
  • Page 33 Group 30: Electrical system Malfunctions Volvo-specific for injectors (MID 128, SID 1– 6) Help Short circuit to battery voltage, injector low voltage side Short circuit to battery negative, injector low voltage or high voltage side Open circuit in injector circuit...
  • Page 34 Malfunctions Group 30: Electrical system Network The system has two types of communication buses. 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.

  • Page 35: Manual Fault Tracing In Bus Cables

    Group 30: Electrical system Malfunctions Manual fault tracing in bus cables Special tools: Multimeter ............. 9812519 IMPORTANT! Cut the current with the main switch before the cables are disconnected. Use the multimeter to check the bus cables. The con- ductors in the bus cables should not be in contact with each other.

  • Page 36: Diagnostic Trouble Codes

    Diagnostic Trouble Codes Group 30: Electrical system Diagnostic Trouble Codes MID 128, PID 45 Inlet air heater status MID 128: Engine control unit FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 37 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- derhead.
  • Page 38 Diagnostic Trouble Codes Group 30: Electrical system FMI 5 Abnormally low current or open circuit Possible reason: • An open circuit in cable harness between EMS 2 and preheat relay. Suitable action: 1. Check the contact pressure in socket 25 in the engine connector B.

  • Page 39: Mid 128, Pid 94

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, PID 94 Fuel pressure MID 128: Engine control unit FMI 1: The sensor value is valid but below the nor- mal working range. FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage.
  • Page 40 Diagnostic Trouble Codes Group 30: Electrical system Fault tracing FMI 1 Fuel pressure is too low Conditions for fault code: The fuel pressure alarm depends on the engine revo- lution. Suitable action: 1. Check fuel level. 2. Open all fuel cocks and check that no leakage occurs.
  • Page 41 Group 30: Electrical system Diagnostic Trouble Codes FMI 5 Abnormally low current or open circuit Conditions for fault code: The voltage on pin B16 on the EMS 2 is less than 0.07 Volt. Possible reason: • An open circuit in fuel sensor 5V supply cable. •...
  • Page 42 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 •...
  • Page 43 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. •...
  • Page 44 Diagnostic Trouble Codes Group 30: Electrical system Checking fuel 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.

  • Page 45: Mid 128, Pid 97

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, PID 97 Water in fuel MID 128: Engine control unit FMI 0: The sensor value is valid but above the nor- mal working range. FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage.
  • Page 46 Diagnostic Trouble Codes Group 30: Electrical system Fault tracing FMI 0 Water in fuel Conditions for fault code: Water in the fuel trap has been detected. Suitable action: 1. Empty the water trap. 2. Check function of water in fuel monitor. FMI 3 Conditions for fault code: The voltage signal on B8 is too high.
  • Page 47 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. Measurement points Nominal value U ≈ Battery voltage x 0.8 Yellow conductor –...

  • Page 48: Mid 128, Pid 100

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, PID 100 Oil pressure MID 128: Engine control unit FMI 1: The sensor value is valid but below the nor- mal working range. FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage.
  • Page 49 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 trol unit (EMS 2) provides pin 1 on the sensor with an splice operating voltage of +5 Volt.
  • Page 50 Diagnostic Trouble Codes Group 30: Electrical system FMI 3 Abnormally high voltage or short circuit to higher voltage Conditions for fault code: The voltage on pin B11 on the EMS 2 is more than 4.95 Volt. Possible reason: • Short circuit between signal cable and 5V supply to oil pressure sensor.
  • Page 51 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. •...
  • Page 52 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. •...
  • Page 53 Group 30: Electrical system Diagnostic Trouble Codes Checking the oil pressure sensor • NOTE! Turn ignition off. • Disconnect the connector from the sensor • Connect adapter cable 885675 between the sen- sor and the engine control unit. • Use multimeter 9812519 for voltage measurement •...

  • Page 54: Mid 128, Pid 105

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, PID 105 Boost temperature MID 128: Engine control unit FMI 0: The sensor value is valid but above the nor- mal working range. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 55 Group 30: Electrical system Diagnostic Trouble Codes Circuit description The boost temperature sensor consists of a thermistor which forms a closed circuit with an internal resistor in splice the engine control unit (EMS 2), via the engine inter- Boost air and face.
  • Page 56 Diagnostic Trouble Codes Group 30: Electrical system FMI 4 Abnormally low voltage or short circuit to lower voltage Conditions for fault code: The voltage on pin B47 on the EMS 2 is less than 0.07 Volt. Possible reason: • Short circuited sensor signal cable to battery neg- ative.
  • Page 57 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 •...
  • Page 58 Diagnostic Trouble Codes Group 30: Electrical system Checking the sensor cable for open circuit or short-circuit: • 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.
  • Page 59 Group 30: Electrical system Diagnostic Trouble Codes Checking boost temperature sensor • NOTE! Cut the current with the main switch. • Connect adapter cable (885675) to the sensor. Do not connect the other end of the adapter cable. • Use multimeter 9812519 to do resistance mea- surement.

  • Page 60: Mid 128, Pid 106

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, PID 106 Boost pressure MID 128: Engine control unit FMI 0: The sensor value is valid but above the nor- mal working range. FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage.
  • Page 61 Group 30: Electrical system Diagnostic Trouble Codes Circuit description The sensor is an active sensor, i.e. the sensor must receive operating voltage. The boost pressure sensor splice measures the absolute pressure, which is the sum of boost air and the boost pressure and atmospheric pressure (300 splice temperature kPa thus corresponds to a boost pressure of 200 kPa...
  • Page 62 Diagnostic Trouble Codes Group 30: Electrical system FMI 3 Abnormally high voltage or short circuit to higher voltage Conditions for fault code: The voltage on pin A22 on the EMS 2 is more than 4.75 Volt. Possible reason: • Short circuited sensor signal cable to 5V voltage or battery voltage.
  • Page 63 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.
  • Page 64 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. •...
  • Page 65 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. Measurement points Nominal value U ≈...

  • Page 66: Mid 128, Pid 108

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, PID 108 Ambient air pressure MID 128: Engine control unit FMI 2: Intermittent or faulty data. FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 67 Group 30: Electrical system Diagnostic Trouble Codes Fault tracing FMI 2, 3, 4 Conditions for fault code: Internal fault in the engine control unit. Suitable action: 1. Replace the engine control unit (EMS 2).

  • Page 68: Mid 128, Pid 110

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, PID 110 Coolant temperature MID 128: Engine control unit FMI 0: The sensor value is valid but above the normal working range. FMI 4: The voltage is less than the normal value or is short circuited to lower volt- age.
  • Page 69 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- gine interface.
  • Page 70 Diagnostic Trouble Codes Group 30: Electrical system FMI 4 Abnormally low voltage or short circuit to lower voltage Conditions for fault code: The voltage on pin B18 on the EMS 2 is less than 0.07 Volt. Possible reason: • Short circuit between both cables to the coolant temperature sensor.
  • Page 71 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. •...
  • Page 72 Diagnostic Trouble Codes Group 30: Electrical system Checking the sensor cable for an open circuit or short-circuit: 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.
  • Page 73 Group 30: Electrical system Diagnostic Trouble Codes Checking coolant temperature sensor • NOTE! Cut the current with the main switch. • Connect adapter cable 885675 to the sensor. Do not connect the other end of the adapter ca- ble. • Use multimeter 9812519 to do resistance mea- surement.

  • Page 74: Mid 128, Pid 111

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, PID 111 Coolant level MID 128: Engine control unit FMI 1: The sensor value is valid but below the nor- mal working range. FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage.
  • Page 75 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 pin B10 on the engine control unit.
  • Page 76 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 •...
  • Page 77 Group 30: Electrical system Diagnostic Trouble Codes Checking coolant switch NOTE! The coolant level monitor can be removed without having to drain the coolant. 1. Undo the connector and remove the level switch from the expansion tank. 2. Use multimeter 9812519 to do resistance mea- surement against the switch.

  • Page 78: Mid 128, Pid 158

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, PID 158 Battery voltage MID 128: Engine control unit FMI 1: The sensor value is valid but below the nor- mal working range. Fault code explanation Bellow range Fault indication DCU: Engine warning in DCU display.
  • Page 79 Group 30: Electrical system Diagnostic Trouble Codes Fault tracing FMI 1 Less than normal working range. Possible reason: Battery voltage less than 24.1V Possible reason: • Altenator belt • Flat / poor batteries • Fault in cables or connectors for battery / alterna- •...

  • Page 80: Mid 128, Pid 164

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, PID 164 Rail pressure MID 128: Engine control unit FMI 0: The sensor value is valid but above the nor- mal working range. FMI 2: Intermittent or faulty data. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 81 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.
  • Page 82 Diagnostic Trouble Codes Group 30: Electrical system FMI 4 Abnormally low voltage or short circuit to lower voltage Conditions for fault code: The voltage on pin A19 on the EMS 2 is less than 0.07 Volt. Possible reason: • Short circuited sensor signal cable to battery neg- ative.
  • Page 83 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 •...
  • Page 84 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. •...
  • Page 85 Group 30: Electrical system Diagnostic Trouble Codes Checking fuel 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.

  • Page 86: Mid 128, Pid 190

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, PID 190 Engine speed MID 128: Engine control unit. FMI 0: The sensor value is valid but above the nor- mal working range. Fault code explanation Engine is / was overspeeding Fault indication DCU: Engine warning in DCU display.

  • Page 87: Mid 128 / Mid 144, Ppid 4

    Group 30: Electrical system Diagnostic Trouble Codes MID 128 / MID 144, PPID 4 Starter input CIU MID 128: Engine control unit. MID 144: DCU/CIU FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 88 Diagnostic Trouble Codes Group 30: Electrical system Fault tracing FMI 3 Abnormally high voltage or short circuit to higher voltage Possible reason: • Faulty start switch. Suitable action: 1. Check that start switch is connected correctly. 2. Check cable harness and connectors between CIU and start switch.

  • Page 89: Mid 128 / Mid 144, Ppid 6

    Group 30: Electrical system Diagnostic Trouble Codes MID 128 / MID 144, PPID 6 Engine stop switch MID 128: Engine control unit MID 144: DCU/CIU FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 90 Diagnostic Trouble Codes Group 30: Electrical system Fault tracing FMI 3 Abnormally high voltage or short circuit to higher voltage Possible reason: • Stop signal activated too long. • Faulty stop button. Suitable action: 1. Check that the stop button isn’t stucked. 2.

  • Page 91: Mid 128, Ppid 19

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, PPID 19 Internal EGR status MID 128: Engine control unit FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to battery negative.
  • Page 92 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.
  • Page 93 Group 30: Electrical system Diagnostic Trouble Codes FMI 5 Abnormally low current or open circuit Possible reason: • An open circuit in one or both of the cables to the IEGR. Suitable action: 1. Check cable harness and connectors between EMS 2 and IEGR.
  • Page 94 Diagnostic Trouble Codes Group 30: Electrical system Checking IEGR coil 1. NOTE! Cut the current with the main switch. 2. Remove the connector from the IEGR solenoid . 3. Use multimeter 9812519 to measure the resis- tance in the IEGR coil. Measurement points Nominal value R ≈...

  • Page 95: Mid 128, Ppid 55

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, PPID 55 ECU temperature MID 128: Engine control unit FMI 0: The sensor value is valid but above the nor- mal working range. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 96 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. •...

  • Page 97: Mid 128, Ppid 98

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, PPID 98 Engine sync acknowledge MID 128: Engine control unit FMI 9: Abnormal updating frequency on the sec- ondary bus. Fault code explanation Communication fault Fault indication DCU Engine warning in DCU display. CIU Flashcode Flash code Electrical fault: None...
  • Page 98 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”...

  • Page 99: Mid 128 / 144, Ppid 132

    Group 30: Electrical system Diagnostic Trouble Codes MID 128 / 144, PPID 132 Throttle input request failure, DCU/CIU MID 128: Engine control unit MID 144: Control interface unit FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to battery negative.
  • Page 100 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 3 Abnormally high voltage or short circuit to higher voltage Possible reason:...
  • Page 101 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.

  • Page 102: Mid 128, Sid

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, SID 1-6 Injector common rail # 1-6 MID 128: Engine control unit. FMI 3: Short to battery voltage, injector low voltage side. FMI 4: Short to battery negative, injector high volt- age side.
  • Page 103 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.
  • Page 104 Diagnostic Trouble Codes Group 30: Electrical system FMI 4 Checking injector circuit Conditions for fault code: Injector activated and faulty voltage in injector high side. Possible reason: • Short circuit to battery negative on the pin on the respective injector’s high voltage side. (EMS 2 pin: 59 and 60) •...
  • Page 105 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.
  • Page 106 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.

  • Page 107: Mid 128, Sid 21

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, SID 21 Speed sensor, camshaft MID 128: Engine control unit. FMI 2: Intermittent or faulty data FMI 3: No signal FMI 8: Abnormal frequency Fault code explanation 2, 3, 8 Faulty sensor / Faulty sensor circuit Fault indication: DCU: Engine warning in DCU display.
  • Page 108 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- sor via a tooth wheel installed on the camshaft. The speed sensor, tooth wheel has 7 teeth, one for each cylinder + one camshaft to determine when cylinder one is to be injected.
  • Page 109 Group 30: Electrical system Diagnostic Trouble Codes FMI 3 Checking sensor circuit Conditions for fault code: No sensor signal when expected. Possible reason: • Incorrectly mounted cam sensor. • An open circuit in any or both of the cables to the cam sensor.
  • Page 110 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. • NOTE! Cut the current with the main switch. • Remove the connector from the sensor. Connect adapter cable 885675 to the connector.
  • Page 111 Group 30: Electrical system Diagnostic Trouble Codes Checking camshaft position sensor 1. NOTE! Cut the current with the main switch. 2. Undo the connector from the sensor and remove the sensor from the cylinder head. Check that the sensor does not have any external damage, or any swarf which has got stuck on it.

  • Page 112: Mid 128, Sid 22

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, SID 22 Speed sensor, crankshaft MID 128: Engine control unit FMI 2: Intermittent or faulty data FMI 3: No signal FMI 8: Abnormal frequency Fault code explanation 2, 3, 8 Faulty sensor / Faulty sensor circuit Fault indication: DCU: Engine warning in DCU display.
  • Page 113 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 crankshaft rpm.
  • Page 114 Diagnostic Trouble Codes Group 30: Electrical system FMI 3 Checking sensor circuit Conditions for fault code: No sensor signal when expected or permanent loss of sensor signal. Possible reason: • Open circuit in any or both of cables to the speed sensor.
  • Page 115 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. • NOTE! Cut the current with the main switch. • Remove the connector from the sensor. •...
  • Page 116 Diagnostic Trouble Codes Group 30: Electrical system Checking speed sensor 1. NOTE! Cut the current with the main switch. 2. Undo the connector from the sensor and remove the sensor from the cylinder head. Check that the sensor does not have any external damage, or any swarf which has got stuck on it.

  • Page 117: Mid 128, Sid 39

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, SID 39 Engine starter relay MID 128: Engine control unit FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 118 Diagnostic Trouble Codes Group 30: Electrical system Fault tracing at starter motor problems: • Check battery condition. • Check wiring to start motor. • Check that starter relay click when start button is activated. FMI 3 Conditions for fault code: Short circuit too battery voltage.
  • Page 119 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.

  • Page 120: Mid 128, Sid 42

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, SID 42 Injection control pressure regulator MID 128: Engine control unit FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 121 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).
  • Page 122 Diagnostic Trouble Codes Group 30: Electrical system FMI 5 The current is less than the normal value or is open circuited 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.
  • Page 123 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. Checking the wiring: • NOTE! Cut the current with the main switch. •...

  • Page 124: Mid 128, Sid 70

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, SID 70 Preheat sense MID 128: Engine control unit FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 125 Group 30: Electrical system Diagnostic Trouble Codes Fault tracing FMI 3 Abnormally high voltage or short circuit to higher voltage Possible reason: • Short circuit to battery voltage in sense wire. • Heating element broken. Suitable action: 1. Check cable harness and connectors to heating element.

  • Page 126: Mid 128, Sid 211

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, SID 211 5V sensor supply 2 MID 128: Engine control unit FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 127 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: •...

  • Page 128: Mid 128, Sid 231

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, SID 231 Communication fault J 1939 MID 128: Engine control unit MID 144: DCU/CIU FMI 2: Intermittent or faulty data. Fault code explanation Communication fault J 1939 Fault indication DCU: Engine warning in DCU display. CIU: Flash code Flash code...
  • Page 129 Group 30: Electrical system Diagnostic Trouble Codes Cable description CAN H-datalink to engine CAN L-datalink to engine Power supply Power supply input Ignition Stop J1708A-datalink to engine J1708B-datalink to engine Fault tracing FMI 2 Checking circuit Conditions for fault code: CAN communication is missing.
  • Page 130 Diagnostic Trouble Codes Group 30: Electrical system Measurements Checking the CAN bus cable. The resistance of the CAN bus termination resistors, one 120 Ω resistor in the ECU and one 120 Ω resistor in the cable harness, are measured. • NOTE! Cut the current with the main switch.

  • Page 131: Mid 128, Sid 232

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, SID 232 5V sensor supply 1 MID 128: Engine control unit FMI 3: The voltage exceeds the normal value or is short circuited to higher voltage. FMI 4: The voltage is less than the normal value or is short circuited to lower voltage.
  • Page 132 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: •...

  • Page 133: Mid 128, Sid 240

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, SID 240 Program memory MID 128: Engine control unit FMI 2: Intermittent or faulty data. FMI 7: Mechanical fault. The system responds in- correctly. FMI 11: Unidentified fault. FMI 14: Special instruction. Fault code explanation 2, 7, 11, 14 Communication fault...

  • Page 134: Mid 128, Sid 254

    Diagnostic Trouble Codes Group 30: Electrical system MID 128, SID 254 Controller error MID 128: Engine control unit MID 144: DCU/CIU FMI 3: RAM addressing failure. FMI 8: Abnormal frequency. FMI 12: Faulty unit or component. Fault code explanation 3, 8, 12 Faulty component Fault indication DCU:...

  • Page 135: Mid 128, Psid 96

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, PSID 96 Rail pressure system MID 128: Engine control unit FMI 0: The sensor value is valid but above the nor- mal working range. FMI 1: The sensor value is valid but below the nor- mal working range.
  • Page 136 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. •...
  • Page 137 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. •...
  • Page 138 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. •...

  • Page 139: Mid 128, Psid 97

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, PSID 97 Rail pressure release valve MID 128: Engine control unit FMI 0: The sensor value is valid but above the nor- mal working range. FMI 7: Mechanical fault. The system responds in- correctly.
  • Page 140 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.
  • Page 141 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.
  • Page 142 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. •...

  • Page 143: J1939 Communication Bus

    Group 30: Electrical system Diagnostic Trouble Codes MID 128, PSID 201 J1939 communication bus MID 128: Engine control unit FMI 9: Abnormal updating rate. Fault code explanation Communication error Fault indication DCU: Engine warning in DCU display. CIU: None Flash code Electrical fault: None Value fault: None...
  • Page 144 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. •...
  • Page 145 Group 30: Electrical system Diagnostic Trouble Codes Measurements Checking the CAN bus cable. The resistance of the CAN bus termination resistors, one 120 Ω resistor in the ECU and one 120 Ω resistor in the cable harness, are measured. • NOTE! Cut the current with the main switch.

  • Page 146: Engine Protection

    Engine protection Group 30: Electrical system Engine protection TAD 650, 660, 750, 760 VE Derate to engine protection map Parameter “Yellow lamp” “Red lamp” 100% Forced to idle Forced shutdown after 5 sec. after 15 sec. High coolant >106 >106 temperature (°C) High boost >90...

  • Page 147: Tad 734 Ge

    Group 30: Electrical system Engine protection Engine protection TAD 734 GE Parameter “Yellow lamp” “Red lamp” Forced shutdown High coolant >106 temperature (°C) High oil temperature (°C) >135 High boost >90 temperature (°C) High boost >355 pressure (kPa) Low coolant level switch switch...

  • Page 148: Wiring Diagrams

    Wiring diagram Group 30: Electrical system Wiring diagrams EMS2, vehicle harness TAD650, 660, 750, 760 VE...

  • Page 149: Wiring Diagram Dcu

    Group 30: Electrical system Wiring diagram EMS 2, engine harness, TAD650, 660, 750, 760 VE Conector (x17) Start relay, supply Internal EGR, supply Internal EGR Start relay Coolant temperature Coolant temperature, ground Oil pressure, ground Fuel pressure, ground 10. Fuel pressure, supply 11.
  • Page 150 Wiring diagram Group 30: Electrical system EMS 2, engine harness, TAD734 GE...
  • Page 151 Group 30: Electrical system Wiring diagram Cable colours BL = Blue LBL = Light blue BN = Brown LBN = Light brown GN = Green GR = Grey OR = Orange = Pink = Red SB = Black VO = Violet = White = Yellow Cable area = 0.75 mm...

  • Page 152: Wiring Diagram Ciu

    Wiring diagram Group 30: Electrical system Cable colors Blue Light blue Brown Light brown Green Grey Orange Pink Black Violet White Yellow Cable area = 0.75 mm unless otherwise specified. Key switch (15+) Alarm, low coolant level RPM potentiometer Fuel alarm Tachometer (code 14) Diagnostic lamp Oil pressure, instrument...

  • Page 153: Technical Data

    Group 30: Electrical system Technical data Technical data Switch, water in fuel Voltage ..................24 V Connector ..................2-pin Contact type ................Closing at detection with water Sensor, fuel pressure Voltage ..................5 V Connector ..................3-pin Working pressure range: .............. 0 – 700 kPa (0 – 7 bar) Pressure signal ................

  • Page 154: Combination Sensor, Boost Pressure/Boost Temperature

    Technical data Group 30: Electrical system Combination sensor, boost pressure/boost temperature Voltage ..................5 V Connector ..................4-pin Working pressure range:: ............. 50 – 400 kPa (0.5-4 bar) Pressure signal ................0.5 – 4.5 V Working temperature range: ............–40°C to +130°C Type ....................

  • Page 155: Index

    Group 30: Electrical system Index...
  • Page 156 Index Group 30: Electrical system...

  • Page 157: References To Service Bulletins

    Group 30: Electrical system References to Service Bulletins References to Service Bulletins Group Date Refers to ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 158 Notes ......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 159 From: ..............................................................Refers to publication: ..........................Publication No.: ........Date of issue: ................Proposal/motivation: ............................................................................................................................................................................................................................................................................................Date: .................. Signed: ................AB Volvo Penta Technical Information Dept. 42200 SE-405 08 Göteborg Sweden...

This manual is also suitable for:

Tad750veTad760veTad734geTad660ve

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