Workshop Manual: Group 30 Electrical System I

Workshop Manual I
Group 30 Electrical system 5(0)
9L, 12L, 13L, 16L

Industrial Engines (EMS 2)
Content
General Information
00-0 General ................................................................................................ 2
Specifications
03-3 Specifications, Electrical ................................................................... 5
Electrical System ........................................................................................ 5
Engine Protection Map ............................................................................... 7
Safety and Other Instructions

05-1 Safety Instructions ........................................................................... 23
Special tools
08-2 Special Service Tools ....................................................................... 27
General, Complete Vehicle Software

30-0 General .............................................................................................. 28
Design and Function ................................................................................ 28
30-2 Fault Tracing ..................................................................................... 62
General ....................................................................................................... 62
Fault Codes ............................................................................................... 64
Measurements ......................................................................................... 138
Cables and fuses

37-0 Wiring Diagrams ............................................................................. 186
Miscellaneous
39-0 General ............................................................................................ 215
Alphabetical index .................................................................................. 217
References to Service Bulletins ............................................................ 219
47701632 10-2012 © AB VOLVO PENTA 1

00-0 General
About this Workshop manual
General information Certified engines
This Service Manual contains technical data, descrip- When carrying out service and repair on emis-
tions and maintenance and repair instructions for sion-certified engines, it is important to be aware
standard model Volvo Penta products. A list of these of the following:
products may be found in the section Specifica-
tions. Certification means that an engine type has been
inspected and approved by the relevant authority.
The product designation and the serial number and The engine manufacturer guarantees that all engines
specification is indicated on the engine decal or type of the same type are manufactured to correspond to
plate. This information must be included in all corre- the certified engine.
spondence regarding the product. This places special demands on service and repair
work, namely:
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified person- • Maintenance and service intervals recom-
nel. It is assumed that any person using the Service mended by Volvo Penta must be complied with.
Manual has a fundamental knowledge of the product • Only spare parts approved by Volvo Penta may
and is able to carry out mechanical and electrical be used.
work to trade standard.
• Service on injection pumps, pump settings and
Volvo Penta continually develops its products; we injectors must always be carried out by an
therefore reserve the right to make changes. All infor- authorized Volvo Penta workshop.
mation in this manual is based on product data which
• The engine must not be converted or modified,
was available up to the date on which the manual was
except with accessories and service kits which
printed. New working methods and significant
Volvo Penta has approved for the engine.
changes introduced to the product after this date are
communicated in the form of Service bulletins. • No changes to the exhaust pipe and engine air
inlet duct installations may be made.
Spare Parts
• No warranty seals (where present on the prod-
Spare parts for the electrical and fuel systems are uct) may be broken by unauthorized persons.
subject to various national safety standards. Volvo
Penta Original Spare Parts meet these standards. No The general instructions in the Operator's Manual
damage of any kind caused by the use of spare parts concerning operation, service and maintenance
not approved by Volvo Penta will be compensated by apply.
any warranty undertaking.
IMPORTANT!
Neglected or poorly-performed care/service and the
use of spare parts not approved by Volvo Penta, will
mean that AB Volvo Penta no longer guarantees that
the engine conforms to the certified model.
Volvo Penta accepts no responsibility for damage or

costs arising as a result of failure to follow the above
mentioned standards.
2 47701632 10-2012 © AB VOLVO PENTA

00-0 General
Repair instructions
Introduction Our mutual responsibility
The working methods described in this manual are Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the tech-
mounted in a holding fixture. Maintenance work is nical specification may dramatically increase the
often carried out in situ, in which case – if nothing else environmental impact of an otherwise reliable sys-
is indicated – using the same working methods as the tem. It is therefore critical that the stated wear toler-
workshop. ances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and
For significance, refer to Safety Information . maintenance schedule must be followed.
! DANGER! Some systems, e.g. fuel systems, often require spe-
cial expertise and test equipment. A number of com-
! WARNING! ponents are factory-sealed, for among other things
environmental reasons. Warranty-sealed compo-
! CAUTION!
nents may not be worked on without authorization to
perform such work.
IMPORTANT!, NOTICE!
are by no means comprehensive since not everything Remember that most chemical products, incorrectly
can be foreseen as service work is carried out in the used, are harmful to the environment. Volvo Penta
most varied of circumstances. We call attention to recommends the use of biodegradable degreasers
risks that may occur due to incorrect handling during whenever components are cleaned, unless otherwise
work in a well-equipped workshop using working specified in the Service Manual. When working out-
methods and tools tried and tested by us. doors, take especial care to ensure that oils and wash
residues etc. are correctly properly for destruction.
The service manual describes work operations car-
ried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Spe-
Tightening torques
cial Tools are designed to ensure the safest and most Tightening torques for vital fasteners that must be
rational working methods possible. It is therefore the applied using a torque wrench are indicated in the
responsibility of anyone using tools or working meth- Service Manual, chapter Tightening torques and in
ods other than those we recommend to ensure that the Manual's work descriptions. All torque indications
no risk of personal injury or mechanical damage is apply to clean threads, bolt heads and mating faces.
present, or that malfunction can result. Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
In some cases, special safety regulations and user required for fasteners, the correct type will be noted
instructions may be in force for the tools and chemi- in the job description.
cals mentioned in the Service Manual. These regu-
lations must always be followed, and no special
Torque, angle tightening
instructions regarding this are to be found in the Serv-
ice Manual. When torque/angle tightening, the fastener is tight-
ened to a specified torque, and tightening then con-
By taking these basic precautions and using common tinues through a pre-determined angle.
sense it will be possible to guard against most ele-
ments of risk. A clean workplace and a clean product Example: For 90° angle tightening, the fastener is
will eliminate many risks of personal injury and mal- turned a further 1/4 turn in one sequence, after the
function. specified tightening torque has been achieved.
Above all, when working on fuel systems, hydraulic

systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost impor-
tance that dirt and foreign objects are kept away, as
malfunctions or shortened service intervals may oth-
erwise result.
47701632 10-2012 © AB VOLVO PENTA 3

00-0 General
Lock nuts Anaerobic agents.

These agents cure (harden) in the absence of air.
Removed locknuts may not be re-used; they must be These preparations are used when two solid compo-
replaced by new ones, as locking properties are nents, e.g. two cast components, are fitted together
impaired or lost with re-use. without a gasket. Common uses are also to lock and
In the case of lock nuts with plastic inserts the tight- seal plugs, stud threads, taps, oil pressure monitors
ening torque indicated must be reduced if the nut has etc.
the same nut height as a standard, all-metal hexag-
onal nut. Hardened anaerobic preparations are glassy and for
Reduce the torque by 25% for bolt sizes of 8 mm or this reason, the preparations are colored to make
larger. them visible. Hardened anaerobic preparations are
In the case of lock nuts with plastic inserts with a high highly resistant to solvents, and old compound can-
nut-height (where the all-metal thread is as high as a not be removed. On re-assembly, it is important to
standard hexagonal nut), the indicated torque carefully degrease and wipe dry components first,
applies. before applying new sealant in accordance with the
instructions.
Strength classes
Safety regulations for fluorocarbon
Nuts and bolts are subdivided into different strength
classes. The classification is shown by a marking on rubber
the bolt head. Markings of a higher number indicate Fluorocarbon rubber is a common material in sealing
stronger material. For example, a bolt marked 10-9 is rings for shafts, and in O-rings, for example.
stronger than one marked 8-8.
When fluorocarbon rubber is exposed to high tem-
For this reason, it is important that when bolts are peratures (above 300°C/572°F), hydrofluoric acid
removed they are returned to their original locations can form. This is highly corrosive. Contact with the
on re-assembly. When replacing bolts check the skin can result in severe chemical burns. Splashes in
applicable Spare parts catalogue to ensure the cor- your eyes can result in chemical wounds. If you
rect bolt is used. breathe in the fumes, your lungs can be permanently
damaged.
Sealing compounds etc.
To ensure service work is correctly carried out it is WARNING!
important that the correct type of sealants and locking Seals must never be cut with a torch, or be burnt
fluids are used on joints where such are required. afterwards in an uncontrolled manner. Risk for
poisonous gases.
In each service manual section concerned, the seal-
ants used in product manufacture are indicated. The
same sealants, or sealants with equivalent proper- WARNING!
ties, must be used for maintenance work. Always use chloroprene rubber gloves (gloves for
chemicals handling) and goggles. Handle the
Make sure that mating surfaces are dry and free from removed seal in the same way as corrosive acid. All
oil, grease, paint and anti-corrosion agent before residue, including ash, can be highly corrosive. Never
applying sealant or locking fluid. Always follow the use compressed air to blow clean.
manufacturer's instructions regarding applicable Put the remains in a plastic container, seal it and
temperatures, hardening times and such. apply a warning label. Wash the gloves under running
Two basic types of compound are used: water before removing them.
RTV preparations (Room Temperature Vulcaniz- The following seals are most probably made from flu-
ing). orocarbon rubber:
Used most often together with gaskets, e.g. sealing Seal rings for the crankshaft, camshaft, idler shafts.
gasket joints, or are brushed on gaskets. RTV seal-
ants are completely visible when the part has been O-rings, regardless of where they are installed. O-
removed. Old RTV sealant must be removed before rings for cylinder liner sealing are almost always
the component is sealed again. Use denatured alco- made of fluorocarbon rubber.
hol.
Please note that seals which have not been
exposed to high temperature can be handled nor-
mally.
4 47701632 10-2012 © AB VOLVO PENTA

03-3 Specifications, Electrical
Electrical System
Technical Data
Switch, water in fuel
Voltage 24 V
Connector 2 pin
Contact type Closes when water is detected
Sensor, fuel pressure

Voltage 5V
Connector 3 pin
Working pressure range 0–700 kPa (0-7 bar) (0–101.5 PSI)
Pressure signal 0.5–4.5 V
Working temperature range -40 °C to +140 °C
Type Linear
Max tightening torque 30 ±5 Nm (22 ±3.7 lbf.ft.)
Speed sensor, crankshaft / camshaft

Connector 2 pin
Working temperature range -40 °C to +130 °C (-40 °F to +262 °F)
Type Inductive sensor
Max. tightening torque 8 ±2 Nm (5.9 ±1.48 lbf.ft.)
Sensor, oil pressure

Voltage 5V
Connector 3 pin
Working pressure range 0–700 kPa (0-7 bar) (0–101.5 kPa)
Type Linear
Max tightening tourque 30 ±5 Nm (22 ±3.7 lbf.ft.)
Combination sensor, air inlet pressure / inlet manifold temperature

Voltage 5V
Connector 4 pin
Working pressure range 50–400 kPa (0.5-4 bar) (7.3–58.0 PSI)
Type Linear/NTC
Sensor, coolant temperature

Voltage 5V
Connector 2 pin
47701632 10-2012 © AB VOLVO PENTA 5

Type NTC
Max. tightening torque 25 Nm (18.4 lbf.ft.)
Switch, coolant level

Connector 2 pin
Contact type Closing with low coolant level
Alternator
Voltage 24 V
Connector 2 pin
Capacity 80 A at 24 V
Starter motor
Voltage 12 V
Connector 1 pol
Capacity 5.5 kW
(TAD1341–1345) (7 kW)
Sensor, crankcase pressure

Voltage 5V
Connector 3 pin
Working pressure range 40–140 kPa (0.4–1.4 bar) (5.8–20.3 PSI)
Type Linear
Combination sensor, oil level / temperature

Voltage 5V
Connector 4 pin
Type NTC
Switch, piston cooling pressure

Connector 2 pin
Contact type Closing for low piston cooling pressure
Combination sensor, air filter pressure/temperature

Voltage Max 24 V
Connector 4 pin
Switch point -5 ±0.5 kPa (-50 ±5 mbar) (-0.73 ±0.073 PSI)
Type NTC
6 47701632 10-2012 © AB VOLVO PENTA

Engine Protection Map

TAD940VE, TAD941VE, TAD942VE, TAD943VE
Parameter Alarm Engine protection

Setting range Default setting Derating level Action
Oil temperature 120-130 °C 125 °C Setting +3 °C Torque reduction(1) /
(248-266 °F) (257 °F) (5.4 °F) Shutdown(2)
Oil pressure Low idle NA 160 kPa 130 kPa Torque reduction(1) /
(23.2 psi) (18.9 psi) Shutdown(2)
Rated speed NA 225 kPa 195 kPa Torque reduction(1) /
Oil level NA Low level NA NA
Piston cooling pressure, NA NA NA NA
>1000 rpm
Coolant temperature 95-101 °C 98 °C Setting +7 °C Torque reduction(1) /
(203-213.8 °F) (208.4 °F) (12.6 °F) Shutdown(2)
Coolant Level - On Low level Torque reduction(1) /
Shutdown(2)
Fuel feed pressure Low idle NA 100 kPa NA NA
(14.5 psi)
Water in Fuel Water present NA NA NA
Crankcase Pressure Rapid pressure - - Torque reduction(1) /
increase Shutdown(2)
Air filter pressure droop NA NA NA NA
Altitude, above sea NA NA 1200 m Automatic derating
(1312 yds)
Inlet manifold temperature NA 80 °C 91 °C Torque reduction(1) /
(176 °F) (195.8 °F) Shutdown(2)
Air inlet pressure NA 325 kPa 350 kPa Torque reduction(1) /
Engine Speed 100-120 % of 115 % of rated Alarm level NA
rated speed speed
1. Versatile.
2. Power Pack
47701632 10-2012 © AB VOLVO PENTA 7

TAD950VE, TAD951VE, TAD952VE

Oil temperature 120-130 °C 125 °C Setting +3 °C Torque reduction
(248-266 °F) (257 °F) (5.4 °F)
Oil pressure Low idle NA 160 kPa 140 kPa Torque reduction
(23.2 psi) (20.3 psi)
Rated speed NA 200 kPa 180 kPa Torque reduction
(29.0 psi) (26.1 psi)
Piston cooling pressure, NA NA NA Torque reduction
>1000 rpm
Coolant temperature 95-101 °C 98 °C Setting +3 °C Torque reduction
(203-213.8 °F) (208.4 °F) (5.4 °F)
Coolant Level - On Low level Torque reduction
(14.5 psi)
Water in Fuel Water present NA NA NA
Crankcase Pressure Rapid pressure - - Torque reduction
increase
Altitude, above sea NA NA 1200 m Automatic derating
(1312 yds)
Inlet manifold temperature NA 80 °C 91 °C Torque reduction
(176 °F) (195.8 °F)
Air inlet pressure NA 325 kPa 350 kPa Torque reduction
(47.1 psi) (50.8 psi)
Engine Speed 100-120 % of 115 % of rated Alarm level Shutdown. On/Off(1)
rated speed speed
1. Off = No shutdown, alarm only.
8 47701632 10-2012 © AB VOLVO PENTA

TAD940GE, TAD941GE

Oil temperature 120-130 °C 125 °C Setting +3 Shutdown. On/Off
(248-266 °F) (257 °F) (5.4 °F)
Oil pressure Low idle NA 160 kPa 130 kPa Shutdown. On/Off
(23.2 psi) (18.9 psi)
1500 rpm NA 250 kPa 220 kPa Shutdown. On/Off
(36.3 psi) (31.9 psi)
1800 rpm NA 300 kPa 270 kPa Shutdown. On/Off
(43.5 psi) (39.2 psi)
Piston cooling pressure, NA NA NA NA
>1000 rpm
Coolant temperature 95-103 °C 98 °C Setting +5 Shutdown. On/Off
(203-217.4 °F) (208.4 °F) (9 °F)
Coolant Level NA Low level Low level Shutdown. On/Off
(21.8 psi)
>1400 rpm NA 300 kPa NA NA
(43.5 psi)
Water in Fuel NA Water in Fuel NA NA
Crankcase Pressure NA Increased pres- Increased pres- Shutdown. On/Off
sure sure
Altitude, above sea NA - >1500 m Automatic derating
(>1640 yds)
Inlet manifold temperature NA 87 °C 92 °C Shutdown. On/Off
(188.6 °F) (197.6 °F)
Air inlet pressure NA 380 kPa 380 kPa Shutdown. On/Off
(55.1 psi) (55.1 psi)
Engine Speed 100-120 % of 120 % of rated Alarm level Shutdown. Off/On
rated speed speed
47701632 10-2012 © AB VOLVO PENTA 9


Oil temperature 120-130 °C 125 °C Setting +3 °C Torque reduction
(248-266 °F) (257 °F) (5.4 °F)
Oil pressure Low idle - 160 kPa 130 kPa Torque reduction
(23.2 psi) (18.9 psi)
Rated speed - 225 kPa 195 kPa Torque reduction
(32.6 psi) (28.3 psi)
Oil level - Min level - -
Piston cooling pressure, - - - Torque reduction
>1000 rpm
Coolant temperature 95-101 °C 98 °C Setting +7 °C Torque reduction
(203-213.8 °F) (208.4 °F) (12.6 °F)
Coolant Level - On Low level Torque reduction
Fuel feed pressure Low idle - 100 kPa - -
(14.5 psi)
Rated speed - 300 kPa - -
(43.5 psi)
Water in Fuel - High level - -
Crankcase Pressure Rapid pressure - - Torque reduction
increase
Air filter pressure droop - 5.0 kPa (0.7 psi) - -
Altitude, above sea - - - Automatic derating
Inlet manifold temperature - 80 °C 90 °C Torque reduction
(176 °F) (194 °F)
Air inlet pressure - 325 kPa 350 kPa Torque reduction
(47.1 psi) (50.8 psi)
Engine Speed 100-120 % of 115 % of rated - -
rated speed speed
Low voltage - 25,5 V - -
10 47701632 10-2012 © AB VOLVO PENTA

TAD1341GE, TAD1342GE, TAD1343GE,

TAD1344GE, TAD1345GE

Oil temperature 120-130 °C 125 °C Setting +5 °C Shutdown
(248-266 °F) (257 °F) (9 °F)
Oil pressure Low idle - 190 kPa 160 kPa Shutdown
(27.6 psi) (23.2 psi)
1500 rpm - 250 kPa 220 kPa Shutdown
(36.3 psi) (31.9 psi)
(43.5 psi) (39.2 psi)
Piston cooling pressure, - 150 kPa 150 kPa Shutdown
>1000 rpm (21.8 psi) (21.8 psi)
Coolant temperature 95-103 °C 102 °C Setting +5 °C Shutdown
(203-217.4 °F) (215.6 °F) (9 °F)
Coolant Level - On Low level Shutdown
(14.5 psi)
>1400 rpm - 200 kPa - -
(29.0 psi)
Crankcase Pressure - Increased pres- Increased pres- Shutdown
sure sure
Inlet manifold temperature - 80 °C 85 °C Shutdown
(176 °F) (185 °F)
Air inlet pressure 1500 rpm - 360 kPa 370 kPa Shutdown
(52.2 psi) (53.7 psi)
(50.8 psi) (52.2 psi)
Engine Speed 100-120 % of 120 % of rated Alarm level Shutdown
rated speed speed
Engine protection can be disabled. For consequences, see VP International Limited Warranty Policy.
47701632 10-2012 © AB VOLVO PENTA 11

TAD1350GE

Oil temperature 120-130 °C 125 °C Setting +5 °C Shutdown / Off(1)
(248-266 °F) (257 °F) (9 °F)
Oil pressure Low idle - 150 kPa 120 kPa Shutdown / Off(1)
(21.8 psi) (17.4 psi)
1800 rpm - 300 kPa 270 kPa Shutdown / Off(1)
(43.5 psi) (39.2 psi)
Piston cooling pressure, - 150 kPa 150 kPa Shutdown / Off(1)
>1000 rpm (21.8 psi) (21.8 psi)
Coolant temperature 95-103 °C 102 °C Setting +5 °C Shutdown / Off(1)
(203-217.4 °F) (215.6 °F) (9 °F)
Coolant Level - On Low level Shutdown / Off(1)
(14.5 psi)
>1400 rpm - 300 kPa - -
(43.5 psi)
Crankcase Pressure - Increased pres- Increased pres- Shutdown / Off(1)
sure sure
Inlet manifold temperature - 80 °C 85 °C Shutdown / Off(1)
(176 °F) (185 °F)
Air inlet pressure - 310 kPa 320 kPa Shutdown / Off(1)
(45.0 psi) (46.4 psi)
Engine Speed 100-120 % of 120 % of rated Alarm level Shutdown / Off(1)
rated speed speed
12 47701632 10-2012 © AB VOLVO PENTA

TAD1351GE, TAD1352GE, TAD1353GE,


Oil temperature 120-130 °C 125 °C Setting +5 °C Shutdown
(248-266 °F) (257 °F) (9 °F)
(21.8 psi) (17.4 psi)
(36.3 psi) (31.9 psi)
(43.5 psi) (39.2 psi)
>1000 rpm (21.8 psi) (21.8 psi)
Coolant temperature 95-103 °C 102 °C Setting +5 °C Shutdown
(203-217.4 °F) (215.6 °F) (9 °F)
(21.8 psi)
>1400 rpm - 300 kPa - -
(43.5 psi)
sure sure
(176 °F) (185 °F)
Air inlet pressure - 310 kPa 320 kPa Shutdown
(45.0 psi) (46.4 psi)
Engine Speed 100-120 % of 120 % of rated Alarm level Shutdown
rated speed speed
47701632 10-2012 © AB VOLVO PENTA 13

TAD1340VE, TAD1341VE, TAD1342VE,


Oil temperature 120-130 °C 125 °C Setting +5 (9 °F) Shutdown / Off(1)
(248-266 °F) (257 °F)
(21.8 psi) (18.9 psi)
Rated speed - 250 kPa 230 kPa Shutdown / Off(1)
(36.3 psi) (33.4 psi)
>1000 rpm (21.8 psi) (21.8 psi)
Coolant temperature 95-102 °C 102 °C Setting +5 (9 °F) Shutdown / Off(1)
(203-215.6 °F) (215.6 °F)
(14.5 psi)
>1300 rpm - 300 kPa - -
(43.5 psi)
Crankcase Pressure - - Rapid pressure Shutdown / Off(1)
increase
Inlet manifold temperature - 80 °C 85 °C Shutdown / Off(1)
(176 °F) (185 °F)
Air inlet pressure(2) - 310 kPa 320 kPa Shutdown / Off(1)
(45.0 psi) (46.4 psi)
Engine Speed 100-120 % of 120 % of rated Alarm level -
rated speed speed

2. Pabs, 2100 rpm at sea level.
14 47701632 10-2012 © AB VOLVO PENTA


TAD1640VE-B, TAD1641VE-B, TAD1642VE-B,
Parameter Warning level Alarm level Engine protection

Parameter for Power Pack Default setting Level Action.
Default / Alternative
Oil temperature 125 °C (257 °F) Setting +5 °C (9 °F) Shutdown. On/Off(1)
Oil pressure Low idle 50 kPa (7.3 psi) 25 kPa (3.6 psi) Shutdown. On/Off(1)
Rated speed 300 kPa (43.5 psi) 275 kPa (39.9 psi) Shutdown. On/Off(1)
Oil level Min level - -
Coolant temperature 105 °C (221 °F) 107 °C (224.6 °F) Shutdown. On/Off(1)
Coolant Level Low level - -
Fuel feed pressure Low idle - 100 kPa (14.5 psi) -
1200 rpm - 250 kPa (36.3 psi) -
Water in Fuel High level - -
Crankcase Pressure Increased pressure - Shutdown. On/Off(1)
Air filter pressure droop 5.0 kPa (0.7 psi) - -
Altitude, above sea - - Automatic derating
Inlet manifold temperature 80 °C (176 °F) 85 °C (185 °F) Shutdown. On/Off(1)
Air inlet pressure Warning map value + 5 Alarm map value + 5 Shutdown. On/Off(1)
kPa (0.7 psi) kPa (0.7 psi)
Engine Speed 120 % - Shutdown. On/Off(1)
1. Off = Disables the function, i.e. no shutdown.
47701632 10-2012 © AB VOLVO PENTA 15

Parameter Warning Alarm level Engine protection

level
Parameter for Mobile Warning Alarm Derate to eng. prot. map Forced shut-
0% 100 % down after 2 sec
Oil temperature 125 °C 127 °C 127 °C 130 °C N/A

(257 °F) (260.6 °F) (260.6 °F) (266 °F)
Oil pressure Warning map Alarm map N/A N/A Alarm map value
value value
Oil level Min level N/A N/A N/A N/A
Coolant temperature 105 °C 107 °C 107 °C 108 °C N/A
(221 °F) (224.6 °F) (224.6 °F) (226.4 °F)
Coolant Level Low level N/A N/A N/A N/A
Fuel feed pressure Warning map N/A N/A N/A N/A
value
Water in Fuel High level N/A N/A N/A N/A
Crankcase Pressure N/A Increased N/A N/A Increased pres-
pressure sure
5.0 kPa 5.0 kPa (0.7 psi)
(0.7 psi)
Air filter pressure droop - 5.0 kPa (0.7 N/A N/A N/A
psi)
Altitude, above sea - - - - Automatic derat-
ing
Inlet manifold tempera- 80 °C 85 °C 85 °C 86 °C N/A
ture (176 °F) (185 °F) (185 °F) (186.8 °F)
Air inlet pressure Warning map Alarm map Alarm map Alarm map N/A
value value value value
Engine Speed 120 % N/A N/A N/A N/A
16 47701632 10-2012 © AB VOLVO PENTA


Oil temperature 120-130 °C 125 °C Setting +5 Shutdown / Off(1)
(248-266 °F) (257 °F) (9 °F)
(23.2 psi) (18.9 psi)
Rated speed - 300 kPa 270 kPa Shutdown / Off(1)
(43.5 psi) (39.2 psi)
>1000 rpm (21.8 psi) (21.8 psi)
Coolant temperature 95-101 °C 98 °C Setting +5 Shutdown / Off(1)
(203-213.8 °F) (208.4 °F) (9 °F)
(14.5 psi)
Rated speed - 300 kPa - -
(43.5 psi)
Crankcase Pressure - - - Shutdown
(176 °F) (185 °F)
Air inlet pressure - 290 kPa 340 kPa Shutdown
(42.1 psi) (49.3 psi)
Engine Speed 100-120 % of 120 % / Off(1) Alarm level Shutdown / On
rated speed
Low voltage - 25.5 V - -
47701632 10-2012 © AB VOLVO PENTA 17

TAD1650VE
Parameter “Yellow “Red Derate 0 % to Derate 70 % Forced Forced shut-

lamp” lamp” eng. prot. map to eng. idle after down after 15
prot. map 5 sec sec
Coolant temperature 98 °C 101 °C 101 °C 106 °C >106 °C >106 °C
(208.4 °F) (213.8 °F) (213.8 °F) (222.8 °F) (222.8 °F) (222.8 °F)
Oil temperature 125 °C 128 °C 128 °C 135 °C - -
(257.0 °F) (262.4 °F) (262.4 °F) (275.0 °F)
High inlet manifold temper- 80 °C 83 °C 83 °C 90 °C >90 °C >90 °C
ature (176.0 °F) (181.4 °F) (181.4 °F) (194 °F) (194 °F) (194 °F)
Parameter “Yellow “Red lamp” Derate 50 % to eng. Forced idle Forced shut-
lamp” prot. map after 5 sec down after 15
sec
High air inlet pressure 30 kPa > 40 kPa > 40 kPa > demand 45 kPa > 45 kPa > demand
demand demand (5.8 psi) demand (6.5 psi)
(4.4 psi) (5.8 psi) (6.5 psi)
Parameter “Yellow “Red lamp” Derate 70 % to eng. Forced idle Forced shut-
lamp” prot. map after 5 sec down after 15
sec
Low Oil Pressure Limit 20 kPa < 20 kPa < limit 25 kPa < 25 kPa < limit
limit (2.9 psi) limit (3.6 psi)
(2.9 psi) (3.6 psi)
Low coolant level Switch - - - -
Low oil level Switch - - - -
Low piston cooling pres- - Switch < Switch < 150 kPa Switch < Switch < 150 kPa
sure 150 kPa (21.8 psi) 150 kPa (21.8 psi)
(21.8 psi) (21.8 psi)
Crankcase Pressure - Rapid pres- Rapid pressure Rapid pres- Rapid pressure
sure increase sure increase
increase increase
y (kPa) Oil pressure limit

x Engine speed
y Oil pressure
z z Oil pressure limit
P0016579 x (rpm)
18 47701632 10-2012 © AB VOLVO PENTA

TAD1640GE, TAD1641GE, TAD1642GE

Oil temperature 120-130 °C 125 °C Setting +5 Shutdown / Off(1)
(248-266 °F) (257 °F) (9 °F)
Oil pressure Low idle, - 190 kPa 160 kPa Shutdown / Off(1)
900 rpm (27.6 psi) (23.2 psi)
(36.3 psi) (31.9 psi)
(43.5 psi) (39.2 psi)
>1000 rpm (21.8 psi) (21.8 psi)
Coolant temperature 95-101 °C 98 °C Setting +5 Shutdown / Off(1)
(203-213.8 °F) (208.4 °F) (9 °F)
Fuel feed pressure Low idle, - 150 kPa - -
900 rpm (21.8 psi)
>1400 rpm - 300 kPa - -
(43.5 psi)
Crankcase Pressure - - - Shutdown
Air filter diff. pressure - 5.0 kPa (0.7 psi) - -
Altitude, above sea - - >1500 m Automatic derating
(>1640 yds)
Inlet manifold temperature - 80 °C 85 °C Shutdown(2)
(176 °F) (185 °F)
Air inlet pressure - 290 kPa 300 kPa Shutdown(2)
(42.1 psi) (43.5 psi)
Overspeed 100-120 % of 120 % / Off(1) Alarm level Shutdown / On(3)
rated speed
1. Off = No shutdown, alarm only. (Only TAD1640-41GE).

2. Only TAD1640-41GE.
3. On = Only TAD1640-41GE.
47701632 10-2012 © AB VOLVO PENTA 19


Oil temperature 120-130 °C 125 °C Setting +5 Shutdown
(248-266 °F) (257 °F) (9 °F)
(21.8 psi) (17.4 psi)
(36.3 psi) (31.9 psi)
(43.5 psi) (39.2 psi)
>1000 rpm (21.8 psi) (21.8 psi)
Coolant temperature 95-105 °C 105 °C Setting +5 Shutdown
(203-221 °F) (221 °F) (9 °F)
(21.8 psi)
>1400 rpm - 300 kPa - -
(43.5 psi)
sure sure
Inlet manifold temperature - 80 °C 85 °C -
(176 °F) (185 °F)
Air inlet pressure - 310 kPa 320 kPa -
(45.0 psi) (46.4 psi)
Engine Speed 100-120 % of 120 % Alarm level Shutdown
rated speed
20 47701632 10-2012 © AB VOLVO PENTA

TWD1643GE

Oil temperature 120-130 °C 125 °C Setting +5 Shutdown. On/Off(1).
(248-266 °F) (257 °F) (9 °F)
Oil pressure Low idle - 190 kPa 160 kPa Shutdown. On/Off(1).
(27.6 psi) (23.2 psi)
1500 rpm - 250 kPa 220 kPa Shutdown. On/Off(1).
(36.3 psi) (31.9 psi)
1800 rpm - 300 kPa 270 kPa Shutdown. On/Off(1).
(43.5 psi) (39.2 psi)
Piston cooling pressure, - 150 kPa 150 kPa Shutdown. On/Off(1).
>1000 rpm (21.8 psi) (21.8 psi)
Coolant temperature 95-103 °C 98 °C Setting +5 Shutdown. On/Off(1).
(203-217.4 °F) (208.4 °F) (9 °F)
Coolant Level - On Low level Shutdown. On/Off(1).
(21.8 psi)
>1400 rpm - 250 kPa - -
(36.3 psi)
Crankcase Pressure - Increased pres- Increased pres- Shutdown. On/Off(1).
sure sure
Altitude, above sea - - >1500 m Automatic derating
(>1640 yds)
Inlet manifold temperature - 80 °C 85 °C Shutdown. On/Off(1).
(176 °F) (185 °F)
Air inlet pressure - 500 kPa 510 kPa Shutdown. On/Off(1).
(72.5 psi) (74.0 psi)
(absolute) (absolute)
Engine Speed 100-120 % of 115 % of rated Alarm level Shutdown. On/Off(1).
rated speed speed
Exhaust Temperature(2) - 610 °C 640 °C Shutdown. On/Off(1).
(1130 °F) (1184 °F)

2. Between HP turbine and LP turbine.
47701632 10-2012 © AB VOLVO PENTA 21

TWD1663GE, TWG1663GE

Oil temperature 120-130 °C 125 °C Setting +5 Shutdown
(248-266 °F) (257 °F) (9 °F)
(27.6 psi) (23.9 psi)
1500 rpm - - - -
(43.5 psi) (39.9 psi)
Piston cooling pressure, N/A N/A N/A N/A
>1000 rpm
Coolant temperature 95-103 °C 103 °C Setting +5 Shutdown
(203-217.4 °F) (217.4 °F) (9 °F)
(21.8 psi)
>1400 rpm - 250 kPa - -
(36.3 psi)
sure sure
(176 °F) (185 °F)
Air inlet pressure - 30 kPa above 40 kPa above Shutdown
demand demand
(4.4 psi) (5.8 psi)
Engine Speed 100-120 % of 115 % of rated Alarm level -
rated speed speed
22 47701632 10-2012 © AB VOLVO PENTA

05-1 Safety Instructions

Safety Information
This Service Manual contains repair instructions,
descriptions and technical data for products or product
designs from Volvo Penta. Ensure that you are using
the correct service manual.
Read the safety information below and the service manual section About this Workshop manual and Repair
instructions carefully before repair and service work is begun.
!
This symbol is used in the service manual and on the product, to call attention to the
fact that this is safety information. Always read such information very carefully.
Safety texts in the manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT!
Is used to draw your attention to something that may cause minor damage or a minor
malfunction to the product or property.
NOTICE! Is used to draw your attention to important information that will facilitate the
work or operation in progress.
This symbol is used on our products in certain cases and refers to important information
in the instruction book. Make sure that warning and information symbols on the engine
are clearly visible and legible. Replace symbols which have been damaged or painted
over.
A compilation of safety precautions that must be taken and risks which must be paid attention to is
presented in the following pages.
47701632 10-2012 © AB VOLVO PENTA 23

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.
24 47701632 10-2012 © AB VOLVO PENTA

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.
Do not touch the connections during start

attempts. Sparking hazard! Do not lean over
batteries.
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.
47701632 10-2012 © AB VOLVO PENTA 25

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.
Fuel delivery pipes must not be bent or straight-

! ened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.
26 47701632 10-2012 © AB VOLVO PENTA

08-2 Special Service Tools
08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools can be ordered from AB Volvo
Penta by specifying the number indicated.
8856
75 p0005125
P0008793
5
4
3
2
1
P0006701
885675 Break-out cable 88890074 Multimeter 9990014 Break-out cable

Adapter cable for sensor test. Used for measurements. Adapter cable EMS2.
p0013275
9990136 Break-out cable 9998482 Measuring tool 9998534 Break-out cable

Adapter cable for relay test. Gauge for connector on control Used with 88890074 Multime-
unit. ter.
VODIA
p0005128
p0008375
9998699 Break-out box 88820047 VODIA, diagnostic 88890016 Break-out cable

Used with 9990014 Break-out tool For use with 9998699 Break-
cable. Complete tool. out box.
88890053 Break-out cable

Used with 88890074 Multime-
ter to measure on the ECU.
47701632 10-2012 © AB VOLVO PENTA 27

30-0 General
30-0 General
Design and Function

EMS 2 (Engine Management
System)
General Information
EMS 2 is an electronic system with CAN communica-
tion (Controller Area Network) for diesel engine con-
trol. The system has been developed by Volvo and
includes fuel control and diagnostic function.
The system consists of a control unit, six unit injectors,

a number of sensors that supply the control unit with
measurements, sockets for diagnosis and functional
checks. The engine can be connected to a communi-
cations interface consisting of a CAN link and a serial
link.
CAN - Controller Area Network

The J1939 CAN link is responsible after all communi-
cation between the engine control unit (EMS 2) and a
communication interface (such as CIU/DCU), except
for diagnostics. Diagnostics are managed by the so-
called J1708/J1587 link. The CAN link is much faster
than the J1708/J1587 link and has been designed to
connect to other components that support the SAE
J1939 protocol, such as instrument panels and trans-
missions.
If a fault develops on the CAN link, signals for the

engine speed potentiometer, and the start and stop
knobs are taken over by the J1708/J1587 link. How-
ever, instrument and indicator lamps are completely
turned off.
If faults occur in both links, the engine starts to idle.

The only way to shut off the engine in this case is to
use the auxiliary stop (AUX-STOP) placed on the
engine’s left side.
28 47701632 10-2012 © AB VOLVO PENTA

30-0 General
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. All data regarding instruments, indicator
lamps, contacts and potentiometers are controlled by
this bus.
The slower J1708/J1587 link handles diagnostic infor-

mation for, among other things, the flashing code. The
P0002060
VODIA diagnosis tool also uses the J1708/J1587 link
to communicate with the system.
DCU - Display Control Unit

DCU is a digital instrument panel that communicates
with the engine control unit via the CAN link. DCU has
several functions, such as:
Engine control
P0002932 - Start, stop, speed control, pre-heating etc.
Monitoring
- Engine speed, boost pressure, boost temperature,
coolant temperature, oil pressure, oil temperature,
engine hours, battery voltage, instantaneous fuel
consumption and fuel consumption (trip fuel).
Diagnostics
- Shows fault codes in text. Lists previous faults.
Parameter setting
- Idling speed, alarm limit for oil temperature/coolant
temperature, droop.
- Preheating for ignition.
Information
- Information about hardware, software and engine
identification.
47701632 10-2012 © AB VOLVO PENTA 29

30-0 General
DU - Display Unit
The DU is an instrument panel which shows engine
working values graphically on an LCD screen. It con-
sists of an computerised unit for permanent installation
in a control panel.
The display communicates via the CAN link. It is con-

nected to the CAN link between the engine control unit
and the CIU or DCU.
P0002061
Monitoring
- Engine speed, boost pressure, boost temperature,
coolant temperature, oil pressure, oil temperature,
fuel pressure, engine hours, battery voltage, instan-
taneous fuel consumption and average fuel con-
sumption (trip fuel).
Diagnostics
- Shows active fault codes in plain language.
Fuel control
The engine’s fuel requirement is analyzed up to 100
times per second (depending on engine rpm). The
engine’s injection amount and injection timing is con-
trolled electronically via fuel valves on the unit injec-
tors.
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.
The control unit checks and controls the unit injectors,

to ensure that the correct volume of fuel is injected into
each cylinder. It calculates and sets the injection angle.
The control is primarily performed using the speed
sensors and the combined sensor for boost pressure/
boost temperature.
The control unit affects the unit injectors via an elec-

tronic signal to the unit injectors’ electromagnetic fuel
valve, which can open and close.
When the fuel valve is open, fuel flows past, through

the unit injectors’ holes and continuing out through the
fuel channel. Fuel is not sprayed into the cylinder in this
position.
When the fuel valve is closed, pressure is built up by

the mechanically driven pump piston in the unit injec-
tor. When sufficient pressure has developed, fuel is
injected into the cylinder via the unit injector’s injector
section.
The fuel valve is re-opened and pressure in the unit

injector decreases at the same time as the fuel injec-
tion to the cylinder stops.
30 47701632 10-2012 © AB VOLVO PENTA

30-0 General
In order to determine when the fuel valve shall open or

close, the control unit has access to signals from sen-
sors and switch contacts.
Calculation of fuel quantity

The quantity of fuel to be injected into the cylinder is
calculated by the control unit. The calculation deter-
mines the time that the fuel valve is closed (when the
fuel valve is closed fuel is sprayed into the cylinder).
The parameters which govern the amount of fuel
injected are:
• Demanded engine speed
• Engine protector functions
• Temperature
• Boost pressure
Altitude correction
The control unit contains an atmospheric pressure
sensor and an altitude compensation function for
engines that operate at high altitude. This function lim-
its the fuel volume in relation to ambient air pressure.
This is to prevent smoke, high exhaust temperature
and to protect the turbocharger from overspeeding.
Diagnostic function
The task of the diagnostic function is to discover and
localize any malfunctions in the EMS 2 system, to pro-
tect the engine and to inform about any problems that
occur.
If a malfunction is discovered, this 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 flash-
ing 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 work-
shops.
In case of serious disturbances, the engine is shut

down completely or the control unit decreases the
power output (depending on the application). Once
again, a fault code is set for guidance in any fault trac-
ing.
47701632 10-2012 © AB VOLVO PENTA 31

30-0 General
Component location
TAD950-952VE
1 2 3 4 5 6
15
8
14
13
11 10
12
P0013950
1 Coolant level sensor 8 Main relay

2 Preheater 9 Oil level/temperature sensor
3 Unit injector 10 Fuel pressure sensor
4 Crankcase pressure sensor 11 Engine control unit (ECU)
5 Extra stop 12 Water in fuel sensor
6 Sensor, air inlet pressure/intake manifold temper- 13 Diagnostic outlet
ature 14 Alternator
7 IEGR valve 15 Main fuse, 10 A
32 47701632 10-2012 © AB VOLVO PENTA

30-0 General
TAD950-952VE
22 16
21
19
18 17
20
P0013951
16 Coolant temperature sensor

17 Piston cooling pressure sensor
18 Oil pressure sensor
19 Starter motor
20 Starter motor relay
21 Speed sensor, crankshaft
22 Speed sensor, camshaft
47701632 10-2012 © AB VOLVO PENTA 33

30-0 General
TAD1250-1252VE
1 2 3 4 5 7
6
8
21
20
10
19 18
11
16 15 14 13 12
17
P0013952
1 Coolant level sensor 11 Starter motor relay

2 Speed sensor, camshaft 12 Speed sensor, crankshaft
3 Unit injector (one for each cylinder) 13 Connector for diagnostic tool, 6-pin
4 Extra stop 14 Engine interface, 8-pin connector
5 Sensor, air inlet pressure/intake manifold temper- 15 Water in fuel sensor
ature 16 Engine control unit (ECU)
6 Main relay 17 OiI level/temperature sensor
7 Fuel pressure sensor 18 Crankcase pressure sensor
8 IEGR valve 19 Oil pressure sensor
9 Coolant temperature sensor 20 Main fuse, 10 A
10 Starter motor 21 Alternator
34 47701632 10-2012 © AB VOLVO PENTA

30-0 General
TAD1250-1252VE
22 23
P0013953
22 Air filter indicator

23 Piston cooling pressure
47701632 10-2012 © AB VOLVO PENTA 35

30-0 General
TAD1340-1345VE, TAD1341-1345GE, TAD1350-1355GE, TAD1360VE-1365VE
1 2 3 4 5
16
15
14
13
11,12 10
STO
P 8
7
9
P0013972
1 Injector 9 Main relay

2 Sensor, air inlet pressure/intake manifold temper- 10 Engine control unit (ECU)
ature 11 Connector for diagnostic tool, 6-pin
3 Oil pressure sensor 12 Engine interface, 8-pin connector
4 Crankcase pressure sensor 13 OiI level/temperature sensor
5 IEGR valve 14 Fuel pressure sensor
6 Water in fuel sensor 15 Alternator
7 AUX stop 16 Pressure drop indicator/air temperature sensor
8 Main fuse
36 47701632 10-2012 © AB VOLVO PENTA

30-0 General
TAD1340-1345VE, TAD1341-1345GE, TAD1350-1355GE, TAD1360VE-1365VE

17
26 27
25
18
24
19
23
21
20
P0013973
22
17 Coolant level sensor 22 Piston cooling oil pressure sensor

18 Coolant temperature sensor 23 Flywheel position and rotation speed sensor
19 Wastegate regulator (TAD1340-1345VE, 24 Camshaft position sensor
TAD1341-1345GE, TAD1350-1355GE) 25 Air filter indicator
20 Starter motor relay 26 Humidity sensor (TAD1360–65VE only)
21 Starter motor 27 Air inlet throttle (TAD1360–65VE only)
47701632 10-2012 © AB VOLVO PENTA 37

30-0 General
TWD1643GE
16 1 2 3 4
15
5
14
13 6
11 10 9 8 7
12
P0013954
1 Coolant level switch 9 Main relay

2 Unit injector (one for each cylinder) 10 Water in fuel sensor
3 Sensor, air inlet pressure/intake manifold temper- 11 Sensor, oil level/oil temperature
ature 12 Fuel pressure sensor
4 Sensor, air filter pressure/air temperature 13 Alternator
5 Wastegate regulator 14 Crankcase pressure sensor
6 Main fuse 15 Diagnosis tool connector
7 Preheat relay 16 Oil pressure sensor
8 AUX stop
38 47701632 10-2012 © AB VOLVO PENTA

30-0 General
TWD1643GE
23 24 17
18
22
19
21 20
P0013955
17 Coolant temperature sensor

18 Exhaust temperature
19 Cold start valve
20 Camshaft position sensor
21 Starter motor
22 Battery connection points
23 Crankshaft sensor
24 Piston cooling switch
47701632 10-2012 © AB VOLVO PENTA 39

30-0 General
TAD1640GE, TAD1641GE, TAD1641VE, TAD1642GE, TAD1642VE, TAD1643VE

1 2
11
4
10
5
12
6
9
8
7
14
13
P0002058
1 Coolant level sensor, in expansion tank 8 Water in fuel sensor

2 Charge air pressure and temperature sensor 9 Oil level and temperature sensor
3 Air filter indicator 10 Fuel pressure sensor
4 Flywheel position and engine speed sensor 11 Crankhouse pressure sensor
5 Fuse 12 Coolant temperature sensor
6 Aux stop 13 Piston cooling pressure sensor (not TAD1650/51GE)
7 Oil pressure sensor 14 Camshaft position sensor
40 47701632 10-2012 © AB VOLVO PENTA

30-0 General
TWD1643GE, TWD1663GE, TWG1663GE

1
2
3
4
10
5
6
9
7 11
8
15
12
14
13
P0002059
1 Coolant level sensor, in expansion tank 9 Oil level and temperature sensor
2 Charge air pressure and temperature 10 Crankhouse pressure sensor
sensor 11 Coolant temperature sensor
3 Oil pressure sensor 12 Exhaust temperature sensor
4 Airfilter indicator 13 Piston cooling pressure sensor
5 Aux stop 14 Flywheel position and engine speed sensor
6 Fuse 15 Camshaft position sensor
7 “Water in fuel” sensor 16 Solenoid valve, drainage, water trap (optional), not shown
8 Fuel pressure sensor in illustration
47701632 10-2012 © AB VOLVO PENTA 41

30-0 General
TAD1650VE
1 2 3
10
7
8 5
66
12
11
P0005187
1 Crankhouse pressure sensor 7 Oil level and temperature sensor

2 Charge air pressure and temperature sensor 8 Water in fuel sensor
3 Flywheel position and engine speed sensor 9 Fuel pressure sensor
5 Aux stop 11 Piston cooling pressure sensor
6 Oil pressure sensor 12 Camshaft position sensor
42 47701632 10-2012 © AB VOLVO PENTA

30-0 General
TAD1650VE

2 Charge air temp and pressure sensor 9 Oil level and temp sensor
3 Air filter indicator 10 Fuel pressure sensor
4 Crank sensor (RPM) 11 Crankhouse pressure sensor
6 Aux stop 13 Camshaft position sensor
7 Oil pressure sensor
47701632 10-2012 © AB VOLVO PENTA 43

30-0 General

TAD1640VE-B, TAD1641VE-B, TAD1642VE-B
1 2 3 4
11
5
10
9 8
12
13
14
P0014323

2 Connection to SCR system (1660-62VE only) 9 Oil level and temp sensor
3 Charge air pressure and temperature 10 Fuel pressure sensor
4 Air filter indicator 11 Crankhouse pressure sensor
5 Flywheel sensor, speed and position 12 Fuel pressure sensor
6 Fuses for SCR system (1660-62VE only) 13 Camshaft position sensor
7 Aux stop 14 Humidity sensor (1660-62VE only)
44 47701632 10-2012 © AB VOLVO PENTA

30-0 General
Component description
Starter motor
During starting, a gear on the starter rotor shaft is
moved axially so that it engages with the ring gear on
the engine’s flywheel. The axial movement as well as
the activation of the starter motor is controlled by a
solenoid on the starter motor.
The starter solenoid in turn is connected via the starter

relay, which is activated when the starter key is turned
to position III/the starter button is pressed.
TWD1643GE, TWD1663GE, TWG1663GE

Wastegate regulator
The TAD1340-1345VE, TAD1341-1345GE,
TAD1350-55GE and TWD1643/TWD1663/
TWG1663GE engine is equipped with a turbocharger
with a wastegate valve. The wastegate valve controls
the amount of exhaust gas flow which should pass
through the exhaust turbine. An electronically control-
led regulation valve, wastegate regulator, which is con-
trolled by the engine control unit controls the air pres-
sure supplied to the wastegate valve. Boost air pres-
sure taken from the inlet manifold is used to control the
amount that the wastegate opens.
P0013528
TAD1340-1345VE, TAD1341-1345GE, 1350-55GE
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30-0 General
Alternator
The alternator is belt driven and is located at the left
front of the engine.
Unit injector
The unit injectors are located under the valve cover,
mounted in the cylinder head.
The engine’s fuel requirement is analyzed up to 100

times per second (depending on engine rpm). The
amount of fuel injected into the engine and the injection
timing are electronically controlled via the unit injec-
tor’s solenoid controlled fuel valves. This means that
the engine always receives the correct volume of fuel
in all operating conditions, which offers lower fuel con-
sumption, minimal exhaust emissions etc.
P0013523
Speed sensor, crankshaft

The sensor is located in the left side of the flywheel
housing.
The flywheel speed sensor is of the inductive type. It

reads off the crankshaft position and speed from
P0008694
grooves in the flywheel. The signal is sent to the control
unit, which calculates injection timing and fuel quantity.
Speed sensor, camshaft

The position sensor is located in the upper timing gear
cover. The camshaft position sensor is of the inductive-
sensor type. The sensor reads off a cogged wheel with
7 cogs. The impulses from the camshaft sensor give
the control unit information about which cylinder is in
P0008694 turn for injection and when it is performed.
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30-0 General
Air inlet pressure / inlet manifold

temperature sensor
The air inlet pressure and intake manifold temperature
are measured via a combined sensor positioned on the
inlet pipe.
The air inlet pressure sensor measures absolute pres-

sure, which is the sum of air inlet pressure and atmos-
pheric pressure. The sensor supplies the control unit
with a voltage signal proportional to the absolute pres-
sure. The sensor receives a reference signal of 5 Volts
from the control unit.
The intake manifold temperature sensor comprises a

non-linear resistor, where the resistance is dependant
on the temperature of the resistor body. The resistance
drops as temperature rises.
Oil pressure sensor

The oil pressure is measured by a sensor located next
to the control unit.
The sensor is fitted in the engine block so that meas-

urements are performed in the lubrication systems
main oil galley. The pressure signal is a voltage signal
proportional to the pressure. The sensor reference
voltage is 5 Volts.
IEGR
Internal exhaust gas recirculation, IEGR, is used for
recirculation of exhaust gases. This for lowering the
emissions from the engine. The IEGR control valve, is
located on the cylinder head under the valve cover.
P0013515
Oil level / temperature sensor

The sensor is located in the oil sump.
The purpose of the level sensor is to detect if the oil

level becomes too low. A current is passed through the
sensor and the voltage measured across it is then pro-
portional to the oil level. An alarm signal is sent when
the oil level is too low. The temperature sensor consists
of a non-linear resistor, where the resistance is
dependent on the temperature of the resistor body.
The resistance drops as temperature rises.
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30-0 General
Air filter pressure / temperature sensor

Air filter pressure and air filter temperature are meas-
ured by a combined sensor placed above the air filter.
The air filter pressure sensor measures absolute pres-

sure, the sum of air filter pressure and atmospheric
pressure. The sensor consists of a monitor that sends
a signal to the control unit when the pressure in the air
filter becomes too high.
The air filter temperature sensor consists of a non-lin-

P0013492
ear resistor, where the resistance is dependant on the
temperature of the resistor body. The resistance drops
as temperature rises.
Crankcase pressure sensor

The sensor is located on top of the engine in the middle
of the valve cover on the engine’s left side.
The pressure signal is a voltage signal proportional to

the pressure. The sensor reference voltage is 5 Volts.
Switch, water in fuel

The switch is located in the lower part of the fuel pre-
filter.
It’s purpose is to detect water in the fuel system.The

switch comprises two copper electrodes, between
which the resistance is measured. When the resist-
ance drops below a certain limit, which indicates that
there is water in the fuel, a warning message is sent to
the control unit.
p0013478
Exhaust temperature sensor

The exhaust temperature sensor consists of a Pt-200
sensor where the resistance changes depending on
exhaust temperature. The resistance increases with
rising exhaust temperature.
P0013504
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30-0 General
Switch, coolant level

The switch is located in the expansion tank.
It’s purpose is to detect if the coolant level in the cooling

system (expansion tank) becomes too low. The switch
is a magnetically sensitive switch. A float located
around the switch affects the switch differently depend-
ing on the coolant level. A alarm signal is sent when
the coolant level is too low.
P0004033
Cold start valve

In order to avoid boiling in the charge air coolers at
different loads and coolant temperatures, the system
is fitted with a cold start valve that is controlled by the
EMS2. The cold start valve is normally open i.e. without
voltage supply the valve is open.
P0013519
Preheat relay
In cold climate the intake air might need to be pre-
heated. This is done by the preheater located on the
intake manifold. The preheater is controlled by the
EMS2 via the pre-heat relay.
P0013963
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30-0 General
Control unit EMS 2

The control unit checks and controls the unit injectors
so that the correct amount of fuel is injected into each
cylinder. It calculates and sets the injection angle.
The control is primarily performed using the speed
sensors and the combined sensor for boost pressure/
boost temperature.
The EMS 2 system processor is located in the control

unit, where it is protected from moisture and vibration.
The processor receives information continuously

about:
• engine speed
• camshaft position
• boost pressure
• boost temperature
• coolant temperature
• oil pressure
• oil temperature
• oil level
• crankcase pressure
• piston cooling pressure
• water in fuel
• fuel pressure
• coolant level
• air filter pressure
• air filter temperature
Information from the sensors provides exact informa-
tion about current operation conditions and allows the
processor to calculate the correct fuel volume, check
engine status etc.
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30-0 General
TAD950-952VE, Coolant temperature sensor

TAD1350-1355GE,
TWD1643GE, The sensor is located in the left rear part of the cylin-
TWD1663GE, der head.
TWG1663GE The sensor senses the coolant temperature and
sends the information to the control unit. The sensor
TAD1250-1252VE comprises a non-linear resistor, where the resistance
is dependant on the temperature of the resistor body.
The resistance drops as temperature rises.
p0004941
Switch, piston cooling

A valve is installed in the oil filter bracket which opens
or closes the oil supply for piston cooling, depending
on oil pressure. If the oil pressure is below 250 kPa
(36.3 PSI) (TAD950-952VE) or 300 kPa (43.5 PSI)
(TAD1250-1252VE), the valve closes the oil supply for
piston cooling.
The piston cooling pressure is monitored by a pressure

monitor. The output signal from the pressure monitor
can only have two distinct positions, on/off, in the same
way as a relay output. The monitor is supplied with
current from the engine control unit. A pre-set pressure
limit of 150 kPa (21.8 PSI) determines when the mon-
itor switches on. The monitor opens if the pressure
exceeds this value.
At idle, the monitor can be closed without a fault code

being set.
Fuel pressure sensor

The sensor measures fuel pressure and is located on
the fuel filter bracket. The sensor is an active sensor,
i.e. the sensor requires a supply voltage of +5 Volt. The
sensor provides an output signal whose voltage is pro-
portional to the pressure that the sensor measures.
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30-0 General
Repair Instructions
General advice on working with EMS
engines
The following advice must be followed to avoid
damage to the engine control unit and other elec-
tronics.
IMPORTANT!
The system must be disconnected from system volt-
age (by cutting the current with the main switch) and
the starter key(s) must be in the 0 position when the
engine control unit connectors are disconnected or
connected.
• Never disconnect the current with the main switches
when an engine is running.
• Never undo a battery cable when the engine is run-
ning.
• Turn the main switches off or disconnect the battery
cables during quick charging of the batteries.
NOTICE! During normal trickle charging, it is not
necessary to turn the main switches off.
• Only batteries may be used for start help. A help
start device can produce a very high voltage and
damage the control unit and other electronics.
• If a connector is disconnected from a sensor, be
very careful to avoid allowing the contact pins to
come into contact with oil, water or dirt.
Electrical Welding
1 NOTICE! Cut the current with the main switch.
IMPORTANT!
The system must be disconnected from system
voltage when the engine control unit connectors are
disconnected or connected.
2 Undo the two connectors from the engine control
unit before any electrical welding starts. Turn the
locking arm down at the same time as the connector
is pulled outwards.
3 Disconnect all connections to the alternator.
Connect the welder earth clamp to the component
to be welded, or as close as possible to the weld
site. The clamp must never be connected to the
P0013966 engine or in such a way that current can pass
through a bearing.
IMPORTANT!
After welding is completed, the disconnected com-
ponents, such as alternator cables and battery
cables must be connected in the correct order.
The battery cables must always be connected last.
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30-0 General
Engine Control Unit (ECU), Replace

IMPORTANT!
The system must be disconnected from system
voltage when the engine control unit connectors are
disconnected or connected.
2 Remove the two connectors from the engine control
unit. Turn the locking arm down at the same time
as the connector is pulled outwards.
3 Change the engine control unit.
4 If the new engine control unit has recently been
programmed:
Start the engine and check whether any fault codes
related to the engine control unit occur.
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30-0 General
Reprogramming a control unit

IMPORTANT!
The CHASSIS ID number must be readily available to
allow the software to be downloaded.
Action:
1 Log in to Volvo Penta Partner Network’s website:
www.vppn.com
2 Choose “Service & Warranty > VODIA > ECU programming”.
3 Follow the instructions under “Select Chassis ID”.
Choose the control units to be reprogrammed and download the software.
The software for the control units is now downloaded to the PDA(1).
4 Take a look under “Settings”, “Software information” in VODIA to check that the
software has been downloaded.
5 Connect the VODIA to the engine (control unit) to be programmed.
6 Start with the engine control unit.
Select “Engine with mounting and equipment” in the VODIA menu.
Select “MID 128 Control unit, programming”.
VODIA will guide you through the entire programming process.
7 NOTICE! Programming must be reported back to Volvo Penta within 28 days.
Log in to Volvo Penta Partner Network’s web site (www.vppn.com).
8 Choose “VODIA” in the left-hand menu.
9 Choose “Report software” in the left-hand menu.
10 Follow the instructions for “Report software”.
Click “Report”.
1. PDA = “Personal Digital Assistant” (palmtop computer).
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30-0 General
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 program
the new control unit until a “Conversion kit” has been
ordered from Volvo Penta.
If the control units have the same part number, the new
control unit can be programmed as usual. Please refer
to Reprogramming a control unit page 54.
If the part numbers do not coincide – proceed as pos-

sible:
1 Have both part numbers available.
2 Log in to Volvo Penta Partner Network’s web site:
www.vppn.com
3 Choose “Service & Warranty > VODIA > Conver-
sion kit / Accessory kit wizard”.
4 Select engine type and function.
5 Select conversion kit(s) and chassis ID.
6 All selections will be shown in a summary. Click
continue if they are correct.
7 Volvo Penta’s database is now updated. It can take
about a minute before a confirmation is sent.
8 Programming of the control unit can now start.
Please refer to Reprogramming a control
unit page 54.
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30-0 General
Checking the starter motor voltage

Tools:
88890074 Multimeter
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.
NOTICE! * Measured on the batteries.
Voltage measurement, check

1 Check that the battery voltage is at least 24.7 V
when unloaded by using 88890074 Multimeter to
measure between the battery poles.
2 Turn the main switch on.
3 Check that the voltage between terminal B+ on the
starter motor and battery negatives connection
point is the same as the battery voltage.
P0008397
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30-0 General
Checking the charging system

Tools:
88890074 Multimeter
Generally about alternators: Fault tracing charging system

The voltage output from an alternator must be limited
Battery check
to prevent the elecrolyte in the battery to evaporate.
The alternator output is regulated (limited) by the volt- 1 Check that all connectors at the battery are cor-
age regulator in the alternator. The maximum current rectly assembled.
that the alternator can deliver at regulated voltage
2 Check the condition of the cables to the bat-
output depends on the alternator revolution. When the
tery.Look for oxidation.
engine is started an excitation current is needed to
“wake up” the alternator. 3 Check the water level in the battery.
NOTICE! It is the consumers (batteries included) 4 Check, if possible, the specific gravity of all cells.
which decides the output current from the alternator.
when no charge
1 Check the alternator belt tension.
2 Check that all connectors at the alternator and
at the battery are correctly assembled.
3 Check the condition of all cables in the charging
system.
4 Regulator fault. Replace regulator.
Measurements when undercharge
1 Engine off. 1 Check the alternator belt tension.
2 Use 88890074 Multimeter to do a voltage meas- 2 Check that all connectors at the alternator and
urement over the battery. The nominal voltage at the battery are correctly assembled.
over a full loaded battery is approx. 25.4 V. 3 Check the condition of all cables in the charging
3 Engine on. Run at 1500 rpm. system.
4 Use 88890074 Multimeter to do a voltage meas- 4 Regulator fault. Replace regulator.

urement over the battery and also over the alter-
when overcharge
nator. The nominal charging voltage over the
battery should be approx. 27.8-28.6 V. 1 Probably regulator fault. Replace regulator.
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30-0 General
Alternator fault tracing

Checking the brushes and the regulator
• NOTICE! Cut the current with the main switch.
• Remove all connectors on the alternator. B+, B-, etc.
• Remove the plastic cover over the diodes. The plas-
tic cover is fixed with two nuts on B1+, B2+, and a
pozidrive screw.
• Remove the three screws that holds the brushes
and the regulator.
Checking the brushes

• Measure the length of the brushes between the
brush mating surface and the brush holder. If any
brush is damaged the brushes should be replaced.
Checking the regulator

• Set 88890074 Multimeter to diode measurement.
• Connect the probes between the brushes. Check
that there is no short circuit.
• Switch the probe points and check that there is no
short circuit.
• NOTICE! If a regulator fault is suspected install a
new regulator and test operate the charge system.
Checking the rotor

• Set 88890074 Multimeter to diode measurement.
• Connect one probe to each slip ring. The multimeter
should show low resistance but not 0 ohm (short
circuit) or infinity (open circuit).
• Check that the slip rings do not have any burn marks
or other damage.
Short circuit test the rotor

1 Set the 88890074 Multimeter to diode measure-
ment.
2 Connect the probes between one of the slip rings
and the stator body. The multimeter should indicate
OL otherwise the rotor has a short circuit.
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30-0 General
Manual fault tracing in bus cables

Tools:
88890074 Multimeter
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.
Disconnect a bus cable at each end and measure the

resistance between the pins to check this. The multi-
meter should show infinite resistance between each
pin. If the resistance is less than infinite, there is a fault.
Measuring the engine cables

Two types of measurements are done on the engine
cable harness, both resistance measurement and volt-
age measurement.
The measurements are done to ensure that no open

circuits or short circuits occur.
If there is an open circuit, the resistance is infinite, and

if there is a short circuit, it is close to zero. The resist-
ance values given in the workshop manual are approx-
imate, and should be regarded as guidelines.
NOTICE! 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 +20 °C (68 °F)
and with a cold engine.
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30-0 General
Malfunctions
Fault code information
• MID (“Message Identification Description”): • SID (“Subsystem Identification Description”):
The MID consists of a number which designates The SID consists of a number that designates a
the control unit that sent the fault code message. component to which the fault code relates (tach-
(e.g. the engine control unit). ometer, for example).
• PID (“Parameter Identification Description”): • PSID (“Proprietary SID”):
The PID consists of a number that designates a The same as the SID, but this is a Volvo-specific
parameter (value) to which the fault code relates component.
(oil pressure, for example).
• FMI (“Failure Mode Identifier”):
• PPID (“Proprietary PID”): FMI indicates the type of fault (please refer to
The same as the PID, but this is a Volvo-specific the FMI table below).
parameter.
• SPN
Suspect Parameter Number
FMI table
SAE standard
FMI Display text SAE text
0 “Value too high” Data valid but above normal operational range.
1 “Value too low” Data valid but below operational range.
2 “Faulty data” Data erratic, intermittent or incorrect
3 “Electrical fault” Voltage above normal or shorted high.
4 “Electrical fault” Voltage below normal or shorted to lower voltage.
5 “Electrical fault” Current below normal or open circuit.
6 “Electrical fault” Current above normal or short circuit to battery negative
7 “Mechanical fault” Mechanical system not responding properly
8 “Mechanical or electrical fault” Abnormal frequency, pulse width or period
9 “Communication fault” Abnormal update rate
10 “Mechanical or electrical fault” Abnormally large variations
11 “Unknown fault” Unidentifiable error.
12 “Component fault” Faulty device or component
13 “Faulty calibration” Calibration value out of range.
14 “Unknown fault” Special instructions
15 “Unknown fault” Reserved for future use
SAE standard
FMI Help
2 Short circuit to battery voltage, injector high voltage side
3 Short circuit to battery voltage, injector low voltage side
4 Short circuit to battery negative, injector low voltage or high voltage side
9 Open circuit in injector circuit.
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30-0 General
General advice
NOTICE! The following must be done before fault trac-
ing continues, to avoid changing functional sensors:
If there is an active / inactive fault code

Remove the connector from the sensor. Check that
there is no oxidation and that the connector pins are
not damaged.
If there is a fault, please refer to the instructions in Fault
tracing of cables and connectors page 62.
NOTICE! 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.
After an action with the connector

Put the connector back. Check if the fault code
becomes inactive.
Check faults that could be related to that specific sen-
sor.
If the fault remains, measure the cables and sensors

to check them, as instructed.
Network
The system has two types of communication buses.
CAN
A data link (CAN bus) links the nodes to each other.
CAN (“Controller Area Network”) is an industrial stand-
ard for distributed systems.
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
together, which exchanges information and benefits
from each other’s services.
The CAN bus is a serial bus and is the primary control

bus.
J1587
The communication bus, J1587, is also used for acces-
sories and for diagnostics.
This is a serial bus in accordance with standard SAE

J1708.
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30-2 Fault Tracing
30-2 Fault Tracing
General
Fault tracing of cables and
connectors
Tools:
88890074 Multimeter
9998482 Measuring tool
Check all connectors visually
Check the following:

• Look for oxidation which can impair contact in con-
nectors.
• Check that terminals are undamaged, that they are
correctly inserted into their connectors, and that the
cable is correctly terminated in the terminal.
• Check that there is good mechanical contact in the
connector. Use a loose pin to check this.
IMPORTANT!
The multi-pin connectors for the engine control unit
must only be checked with 9998482 Measuring
tool.
• Carefully insert 9998482 Measuring tool into the
multi-pin connector. Pull and push the connector in
and out a few times and feel whether the terminal
socket grasps the tool. If the terminal socket does
not grasp, or if it feels slack, the connection pins
should be changed. Please refer to Joining electrical
cables for connectors. Check the secondary locking
in the connector.
• If possible, shake the cables and pull the connectors
during measurement to discover whether the cable
harness is damaged.
• Check that the cables are not damaged. Avoid
clamping cables in tight bends close to the connec-
tor.
• Check the function of the secondary locking.
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30-2 Fault Tracing
Contact problems
Intermittent contact or temporary recurring faults can
be difficult to fault trace, and are frequently caused by
oxidation, vibration or poorly terminated cables.
Wear can also cause faults. For this reason, avoid dis-
connecting a connector unless it is necessary.
Other contact problems can be caused by damage to

pins, sockets and connectors etc.
Shake cables and pull connectors during measure-

ment, to find where the cable is damaged.
Contact resistance and oxidation

Resistance in connectors, cables and junctions should
be approx. 0 Ω. A certain amount of resistance will
occur, however, because of oxidation in connectors.
If this resistance is too great, malfunctions occur. The

amount of resistance that can be tolerated before mal-
functions occur varies, depending on the load in the
circuit.
Open circuit
Possible reasons for faults could be chafed or broken
cables, or connectors which have come undone.
Use the wiring schedule to check the cables which are

relevant to the function. Start off with the most probable
cable in the circuit.
Check the following:

• Disconnect the relevant connector at each end of
the cable harness.
• Use 88890074 Multimeter to measure the resist-
ance between the ends of the cable.
Nominal value ~ 0 Ω.
• If possible, shake the cables and pull the connectors
during measurement to discover whether the cable
harness is damaged.
• Check the next cable system in the wiring schedule
if no fault has been found.
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30-2 Fault Tracing
Fault Codes
MID 128, PID 45 Inlet air heater
status
FMI 3 – Voltage above normal or shorted high

Fault code explanation: Faulty sensor / Faulty sensor circuit
Fault indication: DCU: Engine warning in DCU display.
CIU: Flash code
Flash code
Electrical fault: 5.4
Value fault: None
Symptom: Preheat relay never activated. White smoke for cold start.Start problems in
cold climate.
Conditions for fault code: The voltage on pin B25 or on pin B7 on the EMS2 deviates from normal
voltage value.
Possible reason: Short circuit to battery voltage in cable harness between EMS2 and preheat
relay.
Suitable action: 1 Check all connections on the preheat relay and all cables between
EMS2 and preheat relay.
FMI 4 – Voltage below normal or shorted to lower voltage

CIU: Flash code
Flash code
Value fault: None
Symptom: Induction air is hot. Preheat relay is impossible to turn off. Preheat fuse will
break.
Conditions for fault code: The voltage on pin B25 or on pin B7 on the EMS2 deviates from normal
voltage value.
Possible reason: Short circuit to battery negative in cable harness between EMS2 and preheat
relay.
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30-2 Fault Tracing
FMI 5 – Current below normal or open circuit

CIU: Flash code
Flash code
Value fault: None
Symptom: Preheat relay never activated. White smoke for cold start.Start problems in
cold climate.
Conditions for fault code: The current through pin B25 or through pin B7 on the EMS2 deviates from
normal current value.
Possible reason: Open circuit in cable harness between EMS2 and preheat relay.
2 Check the contact pressure in socket 25 and in socket 7 in the engine
connector B.
p0013470
A Circuit description
OR C In cold climate the intake air might need too be pre-
25
(+)57, 60 R / BL heated. This is done by the preheater located on the
BN intake manifold. The activation of the preheater is con-
7
B trolled by the EMS2 via the preheat relay. EMS2 pin
B25 activates the preheat relay. A sense wire is con-
EMS2 nected between the preheater relay output and B7.
p0013471 The sense wire checks that the preheat element and
the preheat fuse are not damaged.
A Connector B
B Junction point
C Preheat relay
Measurements
Checking the wiring page 138
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30-2 Fault Tracing
MID 128, PID 94 Fuel Delivery

Pressure
FMI 1 – Data valid but below operational range
Fault code explanation: Fuel pressure is too low.
Fault indication: DCU: Engine warning in DCU display
CIU: Flash code
Flash code
Value fault: 3.8
Symptom: None.
Conditions for fault code: The fuel pressure alarm depends on the engine revolution.
Suitable action: 1 Check the fuel level.
2 Open all fuel cocks and check that no leakage occurs.
3 Change all fuel filters. (pre- and fine filter)
4 Check that no fuel hose is squeezed or folded.
5 Check the fuel sensor by control measuring the fuel pressure. (see
workshop manual)
6 Remove and clean the pressure release valve in the fuel feed pump.

CIU: Flash code
Flash code
Value fault: 3.8
Symptom: None.
Conditions for fault code: The voltage on pin B16 on the EMS2 is more than 4,77 Volt.
Possible reason: • Open circuit in the sensors negative cable.
• Short circuited fuel sensor signal cable to 5V voltage or to battery volt-
age.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the fuel sensor and EMS2.
2 Check the contact pressure in socket 18 in the engine connector B.
3 Check the sensor.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 3.8
Symptom: None.
Conditions for fault code: The voltage on pin B16 on the EMS2 is less than 0.07 Volt.
Possible reason: • Open circuit in fuel sensor 5V supply cable.
• Open circuit in fuel sensor signal cable.
• Short circuited sensor signal cable to battery negative.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the fuel sensor and EMS2.
2 Check the contact pressure in socket 16 and 17 in the engine connector
B.
3 Check the sensor.
FMI 7 – Mechanical system not responding properly

Fault code explanation: Fuel pressure is too low.
Fault indication: • Warning is displayed in the tachometer/display.
• An orange lamp flashes in the alarm display.
Symptom: None.
Preconditions: Fuel pressure is too low. Fuel pressure depends on engine revolution speed.
Conditions for fault code: Fuel pressure is lower than the value specified in the engine protection
parameter. For parameters, see Administration page 7.
Suitable action: 1 Check the fuel level.
2 Open all fuel cocks and check that no leakage occurs.
3 Check the fuel hoses to ensure that none have been crushed or kinked.
4 Change the fuel filters (primary and secondary filter).
5 Check the fuel sensor by control measuring the fuel pressure. (see
workshop manual)
6 Check the overflow valve and change it if necessary.
7 Check the feed pump.
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30-2 Fault Tracing
A 2 Circuit description
4
C The sensor is an active sensor, i.e. the sensor must
R 4 1
(+) 17 receive operating voltage. Pin 17 on the engine control
SB
(-) 18 P unit (EMS2) connector B provides pin 1 on the sensor
2
with an operating voltage of +5 Volt. Pin 4 on the sen-
GN /BL
16 3 sor is connected to battery negative via pin 18 on the
EMS2. The output signal from the pressure sensor, pin
B SB D 2 on the sensor to pin 16 on the EMS2, is a voltage
5
EMS2 R / BL P signal that is proportional to the fuel pressure. The out-
1
put signal is linear within the sensors working range.
Some engines has a fuel bleeding pump. The fuel

bleeding pump is used when the fuel system has to be
- +
bled.
p0013472
A Connector B
B Fuel press switch
C Fuel pressure
D Fuel bleeding pump
V 5 Component specification
4 Working range: 0 – 7 bar = 0 – 700 kPa
Supply voltage: 5,00 +/- 0,25 VDC
3
Nominal output voltage at 25 °C and at supply voltage
2
5,00 VDC:
1 0,5 VDC @ 0 bar = 0 kPa
4,5 VDC @ 7 bar = 700 kPa
0
0 100 200 300 400 500 600 700
P0013477 kPa
V Output voltage
KPa Oil pressure
Measurements
Checking supply cable, fuel sensor page 138
Checking negative cable, fuel sensor page 139
Checking the signal cable for interruption or
shortcircuit page 140
Checking fuel pressure sensor page 141
P0002552
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30-2 Fault Tracing
MID 128, PID 97 Water in fuel

indicator
FMI 0 – Data valid but above normal operational range

Fault code explanation: Water in fuel.
CIU: Flash code
Flash code
Value fault: 2.1
Symptom: None.
Possible reason: • Water in the fuel trap has been detected.
• Short circuit between both cables to the water in fuel switch.
Suitable action: 1 Empty the water trap.
2 Check the water in fuel switch.
3 Check the cable harness between water in fuel switch and EMS2.

Fault code explanation: Faulty monitor / Faulty monitor circuit
CIU: Flash code
Flash code
Value fault: 2.1
Symptom: None.
Conditions for fault code: The voltage potential on B8 is too high.
Possible reason: The cable connected to B8 is short-circuited to battery voltage.
Suitable action: 1 Check the cable harness between water in fuel switch and EMS2.
p0013478
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30-2 Fault Tracing
B Circuit description
A A sensor is located in the water trap under the fuel filter.

Its task is to detect whether there is water in the fuel.
The EMS 2 senses the voltage drop between the pins
B10 and B8. The pins are in contact with the fuel. When
there is no water in the fuel, the voltage is 0,8 x battery
10 2 voltage. If there is any water in the fuel, voltage will
SB drop.
8 3 The sensor is connected via pin B10 on the engine

Y control unit to battery negative.
EMS2
p0013479
A Connector B
B Water in fuel
Measurements
Checking supply cable, water in fuel
switch page 142
Checking negative cable, water in fuel
switch page 143
Checking water in fuel switch page 143
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30-2 Fault Tracing
MID 128, PID 98 Engine oil level

Fault code explanation: Oil level too low.
CIU: Flash code
Flash code
Value fault: 5.7
Symptom: Warning indication.
Suitable action: 1 Check the oil level in the engine.
2 Check that no oil leakage occurs.
3 Check the oil level sensor.

Fault code explanation: Faulty sensor / Fault in sensor circuit
CIU: Flash code
Flash code
Value fault: 5.7
Possible reason: • Open circuit in the oil level sensor 5V supply cable.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the sensor and the EMS2.
B.
3 Check the sensor.
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30-2 Fault Tracing
b Circuit description
The oil temperature and the oil level sensor is a com-
GN/SB bined sensor. The oil level sensor, pin1, is fed a current
3 4 1
pulse of approx. 250mA during approx. 600ms and the
SB c voltage output will be sampled three times during this
10 2 3 time. To obtain the oil level the oil temperature has to
4 GN/W be used as a reference due to that the oil level output
voltage will alter depending on the oil temperature.
GR/OR
31
EMS2
P0008588
a Connector A
b Connector B
c Oil temperature and level
Measurements
Checking oil level sensor page 144
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30-2 Fault Tracing
MID 128, PID 100 Engine oil pressure

Fault code explanation: Oil pressure is too low.
CIU: Flash code
Flash code
Value fault: 6.6
Symptom: Power is reduced due to error torque map if the engine protection parameter
is activated.
Conditions for fault code: Oil pressure depends on the engine revolution. Oil pressure exceeds the set
value of the engine protection parameter.
Possible reason: • Too low engine oil level.
• Blocked oil filter.
• Oil leakage.
• Faulty oil pressure sensor.
Suitable action: 1 Check the engine oil level and the 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 the sensor by control measuring the engine

CIU: Flash code
Flash code
Value fault: 6.6
• Short circuit between signal cable and 5V supply to oil pressure sensor.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the oil pressure sensor and EMS2.
3 Check the sensor.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 6.6
Possible reason: • Open circuit in 5V supply cable to oil pressure sensor.
• Open circuit in signal cable to oil pressure sensor.
• Short circuit between signal cable and battery negative to oil pressure
sensor.
• Short circuit between the sensor 5V supply cable and the sensor neg-
ative cable.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the oil pressure sensor and EMS2.
A and in socket 11 in engine connector B.
3 Check the sensor.
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30-2 Fault Tracing
Conn. A Circuit description

(black)
R 4 1 The sensor which measures the oil pressure is an
(+) 7
SB active sensor, i.e. it must have operating voltage.
(-) 11 P
2
The engine control unit, connector A, pin 7, supplies
the sensor, pin 1 with +5 Volt. The sensor, pin 4, is
connected to battery negative via the engine control
unit, connector A, pin 11.
EMS2
Conn. B The output signal from the pressure sensor, pin 2, to
(black) the engine control unit, connector B, pin 11, is a voltage
signal which is proportional to the oil pressure (after
BL / OR
11 the oil filters). The output signal is linear within the sen-
sors working range.
P0013480
a Connector A
b Connector B
c Oil pressure
V 5 Component specification
4 Working range: 0 – 7 bar = 0 – 700 kPa.
Supply voltage: 5,00 +/- 0,25 VDC.
3
2
5,00 VDC:
1 0,5 VDC ≈ 0 bar = 0 kPa
4,5 VDC ≈ 7 bar = 700 kPa
0
0 100 200 300 400 500 600 700
P0013477 kPa
V Output voltage
KPa Oil pressure
Measurements
Checking supply cable, oil pressure
sensor page 144
Checking negative cable, oil pressure
sensor page 145
Checking signal cable, oil pressure sensor page 145
Checking oil pressure sensor page 146
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30-2 Fault Tracing
MID 128, PID 105 Intake manifold

temperature

Fault code explanation: Inlet manifold temperature is too high
CIU: Flash code
Flash code
Value fault: 6.2
Symptom: Engine is derated if the engine protection parameter is activated.
Conditions for fault code: Inlet manifold temperature exceeds the set value of the engine protection
parameter.
Possible reason: • Engine temperature is too high.
• High surrounding temperature. (Faulty air inlet temperature sensor,
only on TAD1250-1252VE and TAD1350-1352GE).
• Dust or dirt on the outside of the intercooler and the radiator.
• Faulty inlet manifold temperature sensor.
Suitable action: 1 Check that the engine temperature is normal.
2 Check the air inlet temperature sensor, only on TAD1250-1252VE and
TAD1350-1352GE.
3 Clean the intercooler and the radiator.
4 Check the inlet manifold temperature sensor.

CIU: Flash code
Flash code
Value fault: 6.2
Conditions for fault code: The voltage on pin A47 on the EMS2 is less than 0.07 Volt.
Possible reason: • Short circuited sensor signal cable to battery negative.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the inlet manifold temperature sen-
sor and EMS2.
2 Check the sensor.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 6.2
Conditions for fault code: The voltage on pin A47 on the EMS2 is more than 4,95 Volt.
Possible reason: • Open circuit in inlet manifold temperature signal cable.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the inlet manifold temperature sen-
sor and EMS2.
2 Check the contact pressure in socket 47 in engine connector A.
3 Check the sensor.
a Circuit description
b The inlet manifold temperature sensor consists of a
thermistor which forms a closed circuit with an internal
resistor in the engine control unit (EMS2). The ther-
mistor resistor changes in a non-linear manner,
depending on the inlet manifold temperature. The
EMS2 provides the circuit with a reference voltage of
P0007209 +5 Volt. The EMS2 measures the voltage drop over the
thermistor via pin 47 and pin 11 on the EMS2. Pin 1 on
a Connector A the sensor is connected to battery negative via pin 11
b Intake manifold temperature on the EMS2. When the inlet manifold air is cold, the
thermistor resistance is high and the EMS2 senses a
high voltage drop. As the inlet manifold air warms up,
the resistance in the thermistor falls and the voltage
drop across it falls.
Please refer to the table, “resistance/temperature” in

this fault code chapter.
Measurements
Checking signal cable voltage, inlet manifold (pres-
sure/)temperature sensor page 147
Checking negative cable, inlet manifold pressure/
temperature sensor page 148
Checking the sensor cable for open circuit or
Checking inlet manifold temperature
sensor page 150
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30-2 Fault Tracing
MID 128, PID 106 Air inlet pressure

Fault code explanation: Air inlet pressure is too high.
CIU: Flash code
Flash code
Value fault: 3.5
is activated.
Conditions for fault code: Air inlet pressure exceeds the set value of the engine protection parameter.
Possible reason: • The wastegate does not function properly.
• Faulty air inlet pressure sensor.
• Wrong turbo compressor unit according to the engine specification.
Suitable action: 1 Check the wastegate functionality. (see workshop manual Group
21-26)
2 Check the air inlet pressure sensor by control measuring the air inlet
pressure using a measuring tap (see workshop manual Group 21-26)
3 Check that the turbo compressor unit is in according the engine speci-
fication.

CIU: Flash code
Flash code
Value fault: 3.5
Symptom: Engine smokes more than normally during acceleration or load increase.
Conditions for fault code: The voltage on pin A22 on the EMS2 is more than 4,77 Volt.
• Short circuited sensor signal cable to 5V voltage or battery voltage.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the air inlet pressure sensor and
EMS2.
2 Check the contact pressure in socket 11 in engine connector A.
3 Check the sensor.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 3.5
Symptom: Engine smokes more than normally during acceleration or load increase.
Possible reason: • Open circuit in air inlet pressure signal cable.
• Open circuit in 5V supply cable to sensor.
• Short circuited air inlet pressure signal cable to sensor negative cable.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the air inlet pressure sensor and
EMS2.
2 Check the contact pressure in socket 7 and 22 in engine connector A.
3 Check the sensor.
a Circuit description
b The sensor is an active sensor, i.e. the sensor must
receive operating voltage. The air inlet pessure sensor
measures the absolute pressure, which is the sum of
the air inlet pressure and atmospheric pressure (300
kPa thus corresponds to a boost pressure of 200 kPa
when atmospheric pressure is 100 kPa).
P0007209 Pin 7 on the engine control unit (EMS2) connector A
provides pin 3 on the sensor with an operating voltage
a Connector A of +5 Volt. Pin 1 on the sensor is connected to battery
b Intake manifold temperature negative via pin 11 on the EMS2. The output signal
from the pressure sensor, pin 4 on the sensor to pin 22
on the EMS2, is a voltage signal that is proportional to
the air inlet pressure. The output signal is linear within
the sensors working range.
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30-2 Fault Tracing
Component specification
Working range 0,5 – 4,0 bar = 50 – 400 kPa
Supply voltage: 5,00 +/- 0,25 VDC

5,00 VDC:
0,5 VDC ≈ 0,5 bar = 50 kPa
4,5 VDC ≈ 4 bar = 400 kPa
P0013490
Measurements
Checking supply cable, inlet manifold pressure
sensor page 150
Checking negative cable, inlet manifold pressure/
temperature sensor page 148
Checking signal cable, inlet manifold pressure
sensor page 151
Checking air inlet pressure sensor page 151
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30-2 Fault Tracing
MID 128, PID 107 Air filter pressure

drop

Fault code explanation: Air pressure is too low.
CIU: Flash code
Flash code
Value fault: 5.6
Symptom: None.
Possible reason: Blocked air filter.
Suitable action: 1 Change the air filter.

CIU: Flash code
Flash code
Value fault: 5.6
Symptom: None.
Conditions for fault code: The voltage on pin A29 on the EMS2 is too high.
Possible reason: • Short circuit between the air pressure switch signal cable and battery
voltage.
• Faulty switch.
Suitable action: 1 Check the cable harness between the air pressure switch and EMS2.
2 Check the switch.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 5.6
Symptom: None.
Possible reason: • Open circuit in the air pressure switch signal cable.
• Short circuit between the air pressure switch signal cable and battery
negative.
• Short circuit between the switch supply cable and the switch negative
cable.
• Faulty monitor.
Suitable action: 1 Check the cable harness between the air pressure switch and EMS2.
3 Check the switch.
15 SB C P 1 Air filter pressure and air filter temperature are meas-
2 ured by a combined switch/sensor placed above the
29 OR
3 4 air filter. The air filter pressure switch measures abso-
lute pressure, the sum of air filter pressure and atmos-
pheric pressure. The switch activates when the air
pressure in the air filter becomes too low (the vacuum
between the air filter and the turbo is too high). The
EMS2 engine control unit measures the voltage drop over the
B pressure switch to detect when the switch has been
SB
18 activated.
31 BL / GN
P0013493
a Connector A
b Connector B
c Air filter pressure and temperature
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30-2 Fault Tracing
Supply voltage: max 24 VDC.
Switching point: -5kPa ±500Pa, -50±5 mbar
P0013492
Measurements
Checking supply cable, air filter pressure
switch page 152
Checking negative cable, air filter pressure
switch page 165
Checking air pressure switch page 152
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30-2 Fault Tracing
MID 128, PID 108 Barometric

pressure
FMI 2 – Data erratic, intermittent or incorrect

Fault code explanation: Plausibility
Fault indication: DCU: None.
CIU: None.
Flash code
Electrical fault: None.
Value fault: None.
Conditions for fault code: Internal fault in the engine control unit.
Suitable action: 1 Replace the engine control unit (EMS 2).

CIU: None.
Flash code
Value fault: None.
Symptom: Ambient pressure is set to 1.0 bar.

CIU: None.
Flash code
Value fault: None.
Symptom: Ambient pressure is set to 1.0 bar.
Circuit description
Sensor is placed inside the engine control unit.
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30-2 Fault Tracing
MID 128, PID 110 Engine coolant

temperature
Fault code explanation: Coolant temperature too high.
CIU: Flash code
Flash code
Value fault: 6.1
Conditions for fault code: Coolant water temperature exceeds the set value of the engine protection
parameter.
Possible reason: • Coolant level too low.
• Dust or dirt on the outside of the radiator.
• Drive belt is not properly adjusted.
• Worn impeller in the coolant pump.
• There is air in the coolant water system.
• Faulty thermostat.
• Faulty temperature sensor.
• Clogged cooling water system.
Suitable action: 1 Check the coolant level.
2 Check the outside of radiator for dust and dirt.
3 Check the drive belt adjustment.
4 Check the impeller in the coolant pump.
5 Bleed the coolant water system.
6 If low coolant level check the coolant water system for leakage by a
pressure test.
7 Check the pressure valve in the coolant cup.
8 Check the coolant water thermostat or change the coolant water ther-
mostat.
9 Check the coolant temperature sensor.
10 Clean the coolant water system.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 6.1
Possible reason: • Short circuit between both cables to the coolant temperature sensor.
• Faulty sensor.
Suitable action: 1 Check the cable harness between coolant temperature sensor and
EMS2.
2 Check the sensor.

CIU: Flash code
Flash code
Value fault: 6.1
Possible reason: • Open circuit in signal cable to temperature sensor.
• Open circuit in negative cable to temperature sensor.
• Faulty sensor.
Suitable action: 1 Check the cable harness between coolant temperature sensor and
EMS2.
B.
3 Check the sensor.
p0004941 TAD1250–1252VE
TAD950–952VE, TWD1643GE,
TWD1663GE, TWG1663GE
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30-2 Fault Tracing
a
The coolant temperature sensor consists of a thermis-
tor which forms a closed circuit with an internal resistor
in the engine control unit (EMS2). The thermistor resis-
tor changes in a non-linear manner, depending on the
GR / W
coolant temperature. The EMS2 provides the circuit
with a reference voltage of +5 Volt. The EMS2 meas-
P0007217
ures the voltage drop over the thermistor via pin 27 and
pin 18 on the EMS2. Pin 1 on the sensor is connected
a Coolant temperature to battery negative via pin 18 on the EMS2. When the
b Connector B
coolant is cold, the thermistor resistance is high and
the EMS2 senses a high voltage drop. As the coolant
warms up, the resistance in the thermistor falls and the
voltage drop across it falls.
Please refer to the table, “resistance/temperature” in
Measurements
Checking signal cable, coolant temperature
switch page 166
Checking negative cable, coolant temperature
switch page 167
Checking coolant temperature sensor page 153
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30-2 Fault Tracing
MID 128, PID 111 Coolant level

Fault code explanation: Coolant level is too low.
CIU: Flash code
Flash code
Value fault: 2.2
Suitable action: 1 Check the coolant level.
2 Bleed the coolant water system.
3 If low coolant level check the coolant water system for leakage by a
pressure test.
4 Check the pressure valve in the coolant cup.
5 Check the wiring to the coolant level switch.
6 Check the coolant level switch.
FMI 3– Voltage above normal or shorted high

Fault code explanation: Faulty switch / Faulty switch circuit
CIU: Flash code
Flash code
Value fault: 2.2
Conditions for fault code: The voltage on pin B23 in the engine control unit is too high.
Possible reason: Short circuit to battery voltage on pin B23.
Suitable action: 1 Check the cable harness between the coolant level switch and the
EMS2.
P0004033
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30-2 Fault Tracing
The coolant level in the engine is monitored by a level
10 B
2 switch. Pin 23 on the engine control unit (EMS2) pro-
SB vides pin 1 on the level switch with supply voltage. Pin
1 2 on the level switch is connected to battery negative
via pin 10 on the engine control unit. The level switch
has two states: On/Off.
23 The level switch consists of two sections, the actual
LBN
EMS2 switch and a magnetic float which is built into the
P0013497 expansion tank. The switch senses the position of the
magnetic float. When the coolant level falls, the float
a Connector B operates the switch and a closed circuit is formed.
b Coolant level
Measurements
Checking supply cable, coolant level
switch page 155
Checking negative cable, coolant level
switch page 155
Checking coolant level switch page 155
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30-2 Fault Tracing
MID 128, PID 153 Crankcase

pressure

Fault code explanation: Crankcase pressure is rising too fast.
CIU: Flash code
Flash code
Value fault: 7.7
Symptom: The engine is shut down if the engine protection parameter is activated.
Conditions for fault code: Crankcase pressure rises too fast.
Possible reason: • Blocked crankcase ventilation.
• Faulty crankcase pressure sensor.
• Worn or damaged cylinder liners, piston or piston rings.
Suitable action: 1 Check whether the crankcase ventilation is blocked. Clean the crank-
case ventilation system.
2 Check all cable and connectors between the EMS2 and the crankcase
pressure sensor.
3 Check the crankcase pressure sensor.
4 Control measure the crankcase pressure.
5 Check whether cylinder liner, piston or piston rings are worn or dam-
aged.

CIU: Flash code
Flash code
Value fault: 7.7
Conditions for fault code: The voltage on pin B28 in the engine control unit exceeds 4.78 Volt.
Possible reason: • Short circuit between sensor signal cable and 5V supply or battery volt-
age to crankcase pressure sensor.
• Open circuit in the sensor negative cable.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the crankcase pressure sensor and
the EMS2.
3 Check the sensor.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 7.7
Conditions for fault code: The voltage on pin B28 in the engine control unit is less than 0.30 Volt.
Possible reason: • Open circuit in the sensor 5 Volt supply.
• Open circuit in the sensor signal cable.
• Short circuited sensor signal cable to battery negative.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the crankcase pressure sensor and
the EMS2.
B.
3 Check the sensor.
a
The sensor which measures the crankcase pressure
is an active sensor, i.e. it must have operating voltage.
The engine control unit, connector B, pin 17, supplies
GN / R the sensor, pin 1 with +5 Volt. The sensor, pin 4, is
connected to battery negative via the engine control
unit, connector B, pin 18.
P0007226
The output signal from the pressure sensor, pin 2, to
the engine control unit, connector B, pin 28, is a voltage
a Crankcase pressure signal which is proportional to the crankcase pressure.
It is the velocity of a rising crankcase sure that trigger
b Connector B
the alarm. The output signal is linear within the sensors
working range.
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30-2 Fault Tracing
Working range: 0.4 – 1.4 bar = 40 – 140 kPa
Supply voltage: 5.00 +/- 0.25 VDC

5.00 VDC:
0.5 VDC @ 0.4 bar = 40 kPa
4.5 VDC @ 1.4 bar = 140 kPa
Measurements
Checking negative cable, crankcase pressure
sensor page 184
Checking signal cable, crankcase pressure
sensor page 184
Checking supply cable, crankcase pressure
sensor page 185
Checking crankcase pressure sensor page 156
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30-2 Fault Tracing
MID 128, PID 158 ECU battery

potential

Fault code explanation: Battery voltage too low.
CIU: Flash code
Flash code
Electrical fault: None (EMS)
Value fault: None (EMS)
Electrical fault: None (CIU)

Value fault: None (CIU)
Symptom: Could be engine starting problems.
Conditions for fault code: Battery voltage less than 25.5 V engine running.
Possible reason: • Altenator belt
• Flat / poor batteries
• Fault in cables or connectors for battery / altenator
• Faulty altenator
Suitable action: 1 Check battery cables.
2 Check / charge batteries.
3 Check altenator and drive belt.
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30-2 Fault Tracing
MID 128, PID 172 Inlet air

temperature
CIU: Flash code
Flash code
Value fault: None.
Symptom: None.
Possible reason: • Short circuit between both cables to the air filter temperature sensor.
• Faulty sensor.
Suitable action: 1 Check the cable harness between air filter temperature sensor and
EMS2.
2 Check the sensor.

CIU: Flash code
Flash code
Value fault: None.
Symptom: None.
Possible reason: • Open circuit in signal cable to the air filter temperature
• Open circuit in negative cable to the air filter temperature sensor.
• Faulty sensor.
Suitable action: 1 Check the cable harness between air filter temperature sensor and
EMS2.
B.
3 Check the sensor.
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30-2 Fault Tracing
Circuit description
The air filter temperature sensor consists of a thermis-
tor which forms a closed circuit with an internal resistor
in the engine control unit (EMS2). The thermistor resis-
tor changes in a non-linear manner, depending on the
air temperature. The EMS2 provides the circuit with a
reference voltage of +5 Volt. The EMS2 measures the
voltage drop over the thermistor via pin 18 and pin 31
P0013492 on the EMS2. Pin 3 on the sensor is connected to bat-
tery negative via pin 18 on the EMS2. When the air into
the filter is cold, the thermistor resistance is high and
A the EMS2 senses a high voltage drop. As the air into
the filter warms up, the resistance in the thermistor falls
15 SB C P 1 and the voltage drop across it falls.
2 Please refer to the table, “resistance/temperature” in
29 OR
3 4 this fault code chapter.
EMS2
B
SB
18
31 BL / GN
P0013493
a Connector A
b Connector B
c Air filter pressure and temperature
Measurements
Checking signal cable, air filter temperature
switch page 157
Checking negative cable, air filter temperature
switch page 158
Checking air inlet temperature sensor page 160
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30-2 Fault Tracing
MID 128, PID 173 Exhaust gas

temperature

Fault code explanation: Exhaust gas temperature is too high.
Fault indication: A red lamp flashes in the alarm panel + audible warning.
Symptom: Engine is derated.
Conditions for fault code: Exhaust temperature exceeds the set value of the engine protection param-
eter. (For parameters, see the engine protection map.)
Suitable action: 1 Check that the exhaust pipe has not been damaged and that there are
no restrictions.
2 Check the sensor.
3 Check the exhaust back pressure.

Fault indication: None.
Symptom: None.
Conditions for fault code: The voltage on pin B44 in the engine control unit is less than 0.07 Volt.
Possible reason: • Short circuit between the sensor signal cable and the sensor negative
cable.
• Faulty sensor.
2 Check the sensor.

Fault indication: None.
Symptom: None.
Conditions for fault code: The voltage on pin B44 in the engine control unit exceeds 4.95 Volt.
Possible reason: • Open circuit in the sensor signal cable.
• Open circuit in the sensor negative cable.
• Faulty sensor.
B.
3 Check the sensor.
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30-2 Fault Tracing
Circuit description
Exhaust temperature sensor consists of a Pt-200 sen-
sor where the resistance changes depending on
exhaust temperature. The resistance increases with
rising exhaust temperature.
Pin 44 on the engine control unit (EMS2) connector B
provides pin 2 on the sensor with an operating voltage
of +5 Volt. Pin 1 on the sensor is connected to battery
negative via pin 18 on the EMS2. The voltage drop
across the sensor changes as exhaust temperature
P0013504
changes.
A
1
1
B
SB 2
(-)18
1
VO
(+)44
2
2
EMS2
P0013505
A Connector B
B Exhaust temperature sensor
Measurements
Checking signal cable, exhaust gas temperature
sensor page 160
Checking negative cable, exhaust gas temperature
sensor page 161
Checking exhaust gas temperature sensor page 161
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30-2 Fault Tracing
MID 128, PID 175 Engine oil

temperature
Fault code explanation: Engine oil temperature too high.
CIU: Flash code
Flash code
Value fault: 5.8
is activated.
Conditions for fault code: Engine oil temperature is too high.
Suitable action: 1 Check the oil level in the engine.
2 Check the coolant level and the engine temperature.
3 Check that no leakage occurs.
4 Check the sensor.
5 Clean the oil cooler system and check the bypass valve for the oil
cooler.
Please refer to more detailed instructions in the “Workshop manual group 22,
Lubrication system”.

CIU: Flash code
Flash code
Value fault: 5.8
Conditions for fault code: The voltage on pin A31 in the engine control unit is less than 0.07 Volt.
Possible reason: • Short circuit between the oil temperature signal cable to the sensor
negative cable.
• Short circuit between the oil temperature signal cable and the sensor
5V supply cable.
• Short circuit between oil temperature signal cable and oil level signal
cable.
• Fault in sensor.
2 Check the sensor.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: 5.8
Conditions for fault code: The voltage on pin A31 in the engine control unit exceeds 4,95 Volt.
Possible reason: • Open circuit in the oil temperature signal cable.
• Open circuit in the oil temperature negative cable.
2 Check the contact pressure in socket 31 in the engine connector A and
in socket 10 in engine connector B.
3 Check the sensor.
Circuit description
The oil temperature and the oil level sensor is a com-
bined sensor. The oil temperature sensor consists of
a thermistor which forms a closed circuit with an inter-
nal resistor in the engine control unit (EMS2). The
thermistor resistor changes in a non-linear manner,
depending on the oil temperature. The EMS2 pro-
vides the circuit with a reference voltage of +5 Volt via
pin 31 in connector A. The EMS2 measures the volt-
age drop over the thermistor via pin 18 and pin 31 on
the EMS2. Pin 4 on the sensor is connected to battery
b negative via pin 18 in connector B on the EMS2. When
the oil is cold, the thermistor resistance is high and the
EMS2 senses a high voltage drop. As the oil warms
GN/SB 4 1 up, the resistance in the thermistor falls and the volt-
3
SB c age drop across it falls.
10 2 3 Please refer to the table, “resistance/temperature” in
4 GN/W
Measurements
a Checking negative cable, oil temperature
switch page 162
Checking signal cable, oil temperature
switch page 163
Checking oil temperature sensor page 164
GR/OR
31
EMS2
P0008588
a Connector A
b Connector B
c Oil temperature and level
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30-2 Fault Tracing
MID 128, PID 190 Engine speed

Fault code explanation: Engine is / was overspeeding
CIU: Flash code
Flash code
Value fault: 2.6
Symptom: Engine speed limited.
Possible reason: Too high engine speed.
Suitable action: 1 After the engine has stopped search for the reason for the high speed.
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30-2 Fault Tracing
MID 128, PPID 3 Starter Output

Fault code explanation: Starter output failure.
Fault indication: EMS: Flashcode
Flash code
Value fault: None.
Symptom: The engine cannot be started.
The engine starts immediately when ignition is turned on.

Preconditions: General check for starter motor problems
• Check the starter motor cables and the connections.
• Check that the starter relay pull during the start attempt.
Possible reason: • Short circuited ignition cable to 5V voltage or to battery voltage.
• Ignition signal activated for too long.
• Faulty start button/key switch.
Suitable action: 1 Check that the key switch is connected correctly.
2 Check cable harness between EMS2 and the CIU key switch.
3 Check the function of the key switch.
4 Faulty start button on the DCU.

Fault code explanation: Starter output failure.
Flash code
Value fault: None.

Conditions for fault code: The voltage on pin B29 in the engine control unit is less than normal voltage.
Possible reason: • Short circuited ignition cable to battery negative.
• Faulty key switch.
Suitable action: 1 Check the ignition cable.
2 Check that the key switch is connected correctly.
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30-2 Fault Tracing

Fault code explanation:
Flash code
Value fault: None.

Conditions for fault code: The voltage on pin B29 in the engine control unit is less than normal voltage.
Possible reason: • Open circuit in ignition cable.
• Faulty start relay.
Suitable action: 1 Check the ignition cable.
2 Check the start relay on the starter motor.
3 Check the prestart relay. (only on TAD1250-1252VE)
Circuit description
The engine control unit pin B29 senses when ignition
is switched on that the start relay coil is intact. When
ignition on there is battery voltage potential on pin B29.
When the starter is activated the voltage potential on
pin B29 drops to 0V. On the TAD950-952VE and on
the TAD1350-1355GE engines there is one starter
relay on the startermotor. The TAD1250-1252VE
engine also has a prestart relay.
Measurements
Checking starter motor relay page 164
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30-2 Fault Tracing
MID 128 / 144, PPID 4 Starter input

sensor

Fault code explanation: Starter input failure.
Fault indication: CIU: Flashcode
Flash code
Electrical fault: 4.7 (EMS)
Electrical fault: 5.2 (CIU)


Possible reason: • Ignition signal activated for too long.
• Faulty key swich.

Fault code explanation: Starter input failure.
Fault indication: CIU: Flashcode
Flash code


Possible reason: • Short circuited ignition cable to battery negative.
• Faulty key swich.
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30-2 Fault Tracing
MID 128, PPID 6 Key off input sensor

Fault code explanation: Faulty circuit.
CIU: Flash code
Flash code

Symptom: Engine can only be stopped using the auxiliary stop.
Conditions for fault code: Engine can only be stopped using the auxiliary stop.
Possible reason: Short circuit between the engine stop signal in engine connector and battery
negative.
Suitable action: 1 Check the stop signal cable between the engine control unit A27 and
the CIU/DCU.
Circuit description
The stop input signal to the engine control unit pin A27
can have one of two signal levels, high/low. The A27
stop input on the EMS2 can be set via a parameter in
Vodia to work in one of two ways.
Either the EMS2 stop input is set to “energized to run”

which means that the stop input signal to the EMS2 pin
A27 must be high in order for the engine to be able to
run or the EMS2 stop input is set to “energized to stop”
which means that the stop input signal on the EMS2
pin A27 must be high in order for the engine to stop.
In the first case the stop input signal level has to be low
to shut down the engine.
In the second case the stop input signal level has to be
high to shut down the engine.
Measurements
Checking stop signal cable between ECU and CIU/
DCU page 165
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30-2 Fault Tracing
MID 128, PPID 8 Piston Cooling Oil

Pressure

Fault code explanation: Piston cooling oil pressure is too low.
CIU: Flash code
Flash code
Value fault: 6.7
Symptom: Engine is derated. The fault code is deactivated at engine speed below 1000
rpm.
Conditions for fault code: Piston cooling pressure is too low.
Suitable action: 1 Re-check the piston cooling pressure. If measurement shows that the
piston cooling pressure is correct, change the piston cooling pressure
switch.

CIU: Flash code
Flash code
Value fault: 6.7
Conditions for fault code: The voltage on pin B14 in the engine control unit exceeds normal voltage
value.
Possible reason: Short circuited piston cooling signal cable to battery voltage.
Suitable action: 1 Check cable harness between EMS2 and the piston cooling switch.
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30-2 Fault Tracing
SB Circuit description
A B
2
A valve is installed in the oil filter bracket which opens
P1 or closes the oil supply for piston cooling, depending
10
SB on oil pressure. If the oil pressure is below 250 kPa
(TAD950-952VE) or 300 kPa (TAD1250-1252VE), the
valve closes the oil supply for piston cooling.
14
GR / R
EMS2 The piston cooling pressure is monitored by a pressure
P0013511 switch. The output signal from the pressure switch, pin
1 to the engine control unit, can only have two distinct
A Connector B positions, on/off. The switch is supplied with current
B Piston cooling pressure from the engine control unit pin 10. A pre-set pressure
limit of 150 kPa determines when it switches on. The
switch opens if the pressure exceeds this value.
At idle, the switch can be closed without a fault code

being set.
Switching point: 150kPa = 1.5bar
Supply voltage: 12-24 VDC
Measurements
Checking negative cable, piston cooling oil tempera-
ture switch page 167
Checking supply cable, piston cooling oil temperature
switch page 168
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30-2 Fault Tracing
MID 128, PPID 19 Internal EGR

Status

CIU: Flash code
Flash code
Value fault: None.
Symptom: IEGR can not be turned on. If the IEGR function would fail (not being acti-
vated) the result will be an increased exhaust production with high NOX and
possible over speeding of the turbocharger.
Conditions for fault code: The voltage on pin B30 on the EMS2 deviates from normal voltage value.
Possible reason: Short circuited IEGR signal cable to 5V voltage or to battery voltage.
Suitable action: 1 Check cable harness between EMS2 and the IEGR.

CIU: Flash code
Flash code
Value fault: None.
Possible reason: Short circuited IEGR signal cable to battery negative.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: None.
Possible reason: Open circuit in one or both of the cables to the IEGR.
2 Check the contact pressure in socket 30, 57 and 60 in the engine con-
nector B.
3 Check the IEGR coil.

Fault code explanation: Mechanical fault.
CIU: Flash code
Flash code
Value fault: None.
Possible reason: • IEGR solenoid mechanically stucked.
• Too low oil pressure to activate the IEGR.
Suitable action: 1 Check the function of the IEGR solenoid.
2 Check the engine oil pressure.
P0013515
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30-2 Fault Tracing
Internal exhaust gas recirculation, IEGR, is like the
name says used for recirculation of exhaust gases.
GN 1
30 This for lowering the emissions from the engine. The
R /BL IEGR control valve, is located on the cylinder head
(+) 57 2
(+) 60 under the valve cover. It is used to regulate the oil
B pressure to the rocker arm shaft and from there to the
EMS2 IEGR double rocker. The IEGR valve is a 2-way sole-
P0013516
noid valve controlled by the engine control unit. When
the IEGR not activated an oil pressure on one side of
a Connector B
the solenoid and the solenoid spring force on the other
b IEGR side of the solenoid keeps the solenoid in balance.
When the IEGR function is activated the solenoid
changes position and the oil pressure to the rocker arm
shaft increases. The solenoid is activated when pin 30
in connector B changes its potential.
Measurements
Checking IEGR wiring page 174
Checking IEGR coil page 168
Checking IEGR solenoid page 169
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30-2 Fault Tracing
MID 128, PPID 55 ECU temperature

Fault code explanation: ECU temperature is too high.
CIU: Flash code
Flash code
Value fault: None.
Symptom: None.
Conditions for fault code: The temperature inside the engine control unit is too high.
Possible reason: • High surrounding temperature.
Suitable action: 1 Check if the surrounding temperature is high or if the EMS 2 unit is
exposed to heat radiation.
2 Change EMS 2 unit.
FMI 4 – Voltage below normal or short circuit to lower voltage

CIU: Flash code
Flash code
Value fault: None.
Symptom: None.
Possible reason: Fault in sensor circuit.
Suitable action: 1 Change EMS 2 unit.

CIU: Flash code
Flash code
Value fault: None.
Symptom: None.
Possible reason: Fault in sensor circuit.
Suitable action: 1 Change EMS 2 unit.
Circuit description
The temperature sensor is installed inside of the EMS
2 unit.
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30-2 Fault Tracing
MID 128, PPID 98 Engine sync

acknowledge
FMI 9 – Abnormal update rate

Fault code explanation: Communication fault.
CIU: Flash code
Flash code
Value fault: None.
Preconditions: NOTICE! If the control panel ONLY communicates on the J1939 communi-
cation and NOT the redundancy of J1587 for start, stop and throttle this fault
code is active in the VODIA and that is normal.
Conditions for fault code: “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 the communication cables to the DCU/CIU.
2 Check the power supply cable between the engine control unit and the
DCU/CIU.
3 Check that the DCU/CIU is programmed for the correct engine type.
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30-2 Fault Tracing
MID 128 / 144, PPID 132 Throttle

calibrated position

Fault code explanation: Faulty throttle potentiometer / Faulty throttle potentiometer circuit
CIU: Flash code
Flash code
Value fault: None.
Symptom: Engine goes to idle. If the accelerator is released at first and then pressed
down again the engine can be forced to run using the idle contact.
Possible reason: • Open circuit in any or all of the throttle signals.
• Short circuited throttle potentiometer signal cable to 5V voltage or to
battery voltage.
• Faulty sensor.
Suitable action: 1 Check that the throttle potentiometer is connected correctly.
2 Check cable harness between CIU and the CIU throttle potentiometer.
3 Check the function of the throttle potentiometer. Check the contact
pressure in socket 2, 3 and 3 in the CIU connector.

Fault code explanation: Faulty throttle potentiometer / Faulty throttle potentiometer circuit
CIU: Flash code
Flash code
Value fault: None.
Possible reason: • Short circuited throttle potentiometer signal cable to battery negative.
• Faulty sensor.
3 Check the function of the throttle potentiometer.
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30-2 Fault Tracing
FMI 9 – Abnormal update rate

Fault code explanation: EMS2 is missing the throttle signal.
CIU: Flash code
Flash code
Value fault: None.
Conditions for fault code: EMS2 receives no throttle signal on the J1939 bus from the CIU.
3 Check the function of the throttle potentiometer.
1 2 3
GN / SB (-)
GN / Y (+)
GN / OR
GN / OR
GN / SB
GN / Y
3 2 30
CIU
P0013518
A Throttle pot.
Measurements
Vodia logging throttle signal page 185
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30-2 Fault Tracing
MID 128, PPID 332 Thermostat

Fault code explanation: Faulty sensor / Faulty circuit
CIU: None.
Flash code
Value fault: None.
Possible reason: • Short circuited coldstart valve signal cable to 5V voltage or to battery
voltage.
• Faulty coldstart valve.
Suitable action: 1 Check all cable and connectors between EMS2 and coldstart valve.
2 Check coldstart valve.

CIU: None.
Flash code
Value fault: None.
Possible reason: • Short circuited coldstart valve signal cable to battery negative or to
lower voltage.

CIU: None.
Flash code
Value fault: None.
Possible reason: • Open circuit in coldstart valve signal cable.
• Open circuit in coldstart valve battery voltage cable.
2 Check contact pressure in socket 34 engine connector B.
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30-2 Fault Tracing
Circuit description
In order to avoid boiling in the charge air coolers at
different loads and coolant temperatures, the system
is fitted with a cold start valve that is controlled by the
EMS2. The cold start valve is normally open i.e. without
voltage supply the valve is open. The cold start valve
P0013519
is supplied with battery voltage at pin 4. Pin 1 is con-
nected to pin B34 at the EMS2. When the cold start
valve is activated(valve closes) pin B34 alter its voltage
potential from battery voltage to approx. 0.2 Volt.
VO If the intake manifold temperature signal or the coolant
34 1
temperature signal is lost the cold start valve opens.
R /BL
(+)57,60 4
Under normal conditions, the cold start valve is opened
A B
at:
intake manifold temperature>50° AND coolant water
EMS2 temperature<86°.
P0013520
Under normal conditions, the cold start valve is closed
A Junction point at:
intake manifold temperature<45° OR coolant water
B Cold start valve
temperature>92°.
Measurements
Checking supply cable, coldstart valve page 170
Checking negative cable, coldstart valve page 171
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30-2 Fault Tracing
MID 128, SID 1/2/3/4/5/6 Injector # 1-6

(Short to battery voltage, injector low voltag side)
Fault code explanation: Fault in the injection system.
CIU: Flash code
Flash code
Electrical fault: 7.1–7.6
Value fault: None.
Symptom: Faulty unit injector is shut off, engine runs on 5 cylinders. Limp home on rest
of unit injectors. Engine performance is reduced. Abnormal sound.
Preconditions: NOTICE! Identify which injector by the SID number.
Conditions for fault code: Injector activated and faulty voltage in injector low side.
Possible reason: • Short circuit to battery voltage on the pin on the respective injector’s
low voltage side. (EMS2 pin: 36, 40, 44, 48, 52, 56 and 12, 16, 20, 24,
28, 32)
• Short circuit between high voltage and low voltage sides.
• Short circuit to battery voltage in low voltage injector wire.
Suitable action: 1 Check the cable harness between injectors and engine control unit
(EMS2).

(Short to battery negative, injector high voltage side)
CIU: Flash code
Flash code
Value fault: None.
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. (EMS2 pin: 59, 60, 61 and 62)
• Short circuit to battery negative in high voltage injector wire.
(EMS2).
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30-2 Fault Tracing

(Break in injector circuit.)
CIU: Flash code
Flash code
Value fault: None.
Conditions for fault code: Injector activated and faulty voltage in injector high or low side.
Possible reason: • Open circuit in low voltage wiring side or high voltage wiring side.
If three injection fault codes are set there is an Open circuit on the high
side. If one injection fault code is set there is an Open circuit on the low
side.
• Short circuit to battery voltage on the pin on the respective injector’s
high voltage side. (EMS2 pin: 59, 60, 61 and 62)
• Short circuit to battery negative on the pin on the respective injector’s
low voltage side. (EMS2 pin: 36, 40, 44, 48, 52, 56 and 12, 16, 20, 24,
28, 32)
(EMS2).
2 Check the contact pressure in all sockets regarding the unit injectors in
engine connector A.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: None.
Conditions for fault code: Injector activated and cylinder balancing above limit.
If a fault code is set when the engine has an unsymmetrical load it can not
be rectified. At idle speed the engine control unit is trying to compensate for
uneven running by adding more or less fuel to the injectors, cylinder balanc-
ing. If the engine load is too unsymmetrical the compensation is not enough
and a fault code will be set.
Possible reason: • Unsymmetrical load of the engine.
• Poor / uneven compression.
• Faulty injector.
Suitable action: 1 Clear the fault code with the Vodia tool. Let the engine run at idle speed
without any load and see if the faultcode reappear.
2 Perform test of cylinder compression using the VODIA tool.
3 Change only the faulty injector.
FMI 12 – Faulty device or component

(Low unit injector hold current)
CIU: Flash code
Flash code
Value fault: None.
Conditions for fault code: Low injector hold current. Injector activated.
Possible reason: Intermittent fault.
Suitable action: 1 Check the cables between the injector and the engine control unit.
2 Check the contact pressure in all sockets regarding the unit injectors in
engine connector A.
3 Check the cable connection to the injector.
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30-2 Fault Tracing
a
Circuit description
Y
b
20
24 Y
1 The Delphi E3 electronic unit injectors used on the tier3
59 Y engines have two electronically controlled solenoids.
12
Y Each solenoid is individual controlled by the engine
16 Y
2 control unit.
Y
62 The unit injectors receive voltage from pin 59, 60, 61
Y or 62 on the engine control unit. To activate a unit
28 3
32 Y injector solenoid the engine control unit connects the
unit injectors low side to battery negative.
52 Y
4
56 Y
60 Y
44 Y
48 Y 5
61 Y
Y
36
40 Y 6
P0008674
a Connector A
b Cylinder
Measurements
Trimming the injector page 172
Checking the injector wiring page 173
P0013523
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30-2 Fault Tracing
MID 128, SID 21 Engine position

CIU: Flash code
Flash code
Value fault: None.
Symptom: The engine start time will increase, uses only crankshaft sensor.
Conditions for fault code: Incorrect timing.
Possible reason: • Polarity fault. The cables to the cam speed sensor is shifted.
• Intermittent fault.
• Incorrectly mounted cam speed sensor.
Suitable action: 1 Check the cable harness between the cam speed sensor and EMS2.
2 Check that the cam speed sensor is connected as in the circuit descrip-
tion.
3 Check the cam speed sensor.

(No signal)
CIU: Flash code
Flash code
Value fault: None.
Conditions for fault code: No camsignal when expected.
Possible reason: • Incorrectly mounted cam speed sensor.
• Open circuit in any or both of the cables to the crank speed sensor.
• Short circuit between the cables to the cam speed sensor.
• Faulty cam speed sensor.
Suitable action: 1 Check the installation of the cam speed sensor.
2 Check the cable harness between the cam speed sensor and EMS2.
3 Check the cam speed sensor.
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30-2 Fault Tracing
FMI 8 – Abnormal frequency, pulse width or period

CIU: Flash code
Flash code
Value fault: None.
Conditions for fault code: Incorrect sensor signal.
Possible reason: • Incorrectly mounted cam speed sensor.
• Electrical interference in the cam speed signal.
Suitable action: 1 Check wiring between cam spped sensor and EMS2.
2 Check the installation of the cam speed sensor.
3 Attempt to localize the source of interference.
4 Check and clean the cam speed sensor.
a
Circuit description
b
The camshaft sensor is an inductive sensor. The cam-
shaft sensor is used in the first instance to determine
the cylinder which is next in line for injection. A toothed
wheel installed on the camshaft is used to determine
the cylinder which is next in line for injection. The
toothed wheel has 7 teeth, one for each cylinder plus
P0007250 an extra tooth for cylinder 1. When the camshaft with
toothed wheel rotates, impulses are generated in the
a Connector A sensor. The impulses generated by in the sensor is
used by the engine control unit to determine the cyl-
b Engine speed sensor, camshaft
inder which is next in line for injection.
Measurements
Checking camshaft sensor wiring page 174
Checking camshaft sensor page 175
P0008694
TAD950–952VE
TAD1350–1352GE TAD1250–1252VE
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30-2 Fault Tracing
MID 128, SID 22 Timing sensor,

crank
CIU: Flash code
Flash code
Value fault: None.
Symptom: Engine is difficult to start, uses only cam sensor.
Conditions for fault code: Incorrect signal.
Possible reason: • Short circuit between the cables to the flywheel sensor.
• Polarity fault. The cables to the flywheel sensor is shifted.
Suitable action: 1 Check the cable harness between the flywheel sensor and EMS2.
2 Check that the flywheel sensor is connected as in the circuit description.
3 Check the flywheel sensor.

(No signal)
CIU: Flash code
Flash code
Value fault: None.
Symptom: Engine is running with imprecise timing causing risk of high fuel consumption
and smoke. Cylinder balancing not working with risk of uneven running.
Conditions for fault code: No cranksignal when expected or permanent loss of sensor signal.
Possible reason: • Open circuit in any or both of the cables to the flywheel sensor.
• Incorrectly mounted flywheel sensor.
• Faulty flywheel sensor.
Suitable action: 1 Check the cable harness between the flywheel sensor and EMS2.
2 Check the installation of the flywheel sensor.
3 Check the flywheel sensor.
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30-2 Fault Tracing

CIU: Flash code
Flash code
Value fault: None.
Symptom: Engine is difficult to start, uses only cam sensor.
Conditions for fault code: Incorrect flywheel sensor signal.
Possible reason: • Incorrectly mounted flywheel sensor.
• Electrical interference in the flywheel signal.
Suitable action: 1 Check wiring between flywheel sensor and EMS2.
2 Check the installation of the flywheel sensor.
3 Attempt to localize the source of interference.
4 Check and clean the flywheel sensor.
Circuit description
The flywheel sensor is an inductive sensor. The fly-
wheel sensor is used to monitor engine speed. It is
also used to measure the cylinder acceleration. The
flywheel has three times eighteen depressions for one
rotation. These depressions are detected by the fly-
wheel sensor and generate a pulsed signal which the
engine control unit uses to detect flywheel rotation
speed. Two cylinders share one sector of the depres-
sions (cylinders 1 and 6, 2 and 5, 3 and 4) on the fly-
a Connector A
wheel. This means that it is not possible to know which
b Engine speed sensor, crankshaft cylinder.
Measurements
Checking flywheel sensor wiring page 176
Checking flywheel sensor page 177
P0008694
TAD950-952VE,
TAD1350-1352GE,
TWD1643GE, TWD1663GE,
TWG1663GE TAD1250-1252VE
47701632 10-2012 © AB VOLVO PENTA 123

30-2 Fault Tracing
MID 128, SID 32, Wastegate output

driver
Fault code explanation: Faulty regulator / Faulty regulator circuit
CIU: None.
Flash code
Value fault: None.
Possible reason: • Short circuited wastegate regulator signal cable to 5V voltage or to bat-
tery voltage.
• Faulty wastegate regulator.
Suitable action: 1 Check all cable and connectors between EMS2 and wastegate regu-
lator.
2 Change wastegate regulator.

CIU: None.
Flash code
Value fault: None.
Possible reason: • Open circuit in wastegate battery voltage supply cable.
• Short circuited wastegate regulator signal cable to battery negative or
to lower voltage.
lator.
124 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing

CIU: None.
Flash code
Value fault: None.
Possible reason: • Open circuit in wastegate regulator signal cable.
• Open circuit in wastegate regulator battery negative cable.
lator.
2 Check contact pressure in socket 38 engine connector B.
P0013528
TAD1340-1345VE,
TAD1341-1345GE, TWD1643GE, TWD1663GE,
TAD1350-55GE TWG1663GE
47701632 10-2012 © AB VOLVO PENTA 125

30-2 Fault Tracing
Circuit description
38 GN
2
(+)57,60 R / BL 1 The engine is equipped with a turbocharger with a
(-)58,59 SB 7 wastegate valve. The wastegate valve controls the
C amount of exhaust gas flow which should pass through
B the exhaust turbine. An electronically controlled regu-
lation valve, wastegate regulator, which is controlled
A EMS2
by the engine control unit controls the air pressure
P0013529
supplied to the wastegate valve. Air pressure taken
TWD1643GE, TWD1663GE, TWG1663GE from the inlet manifold is used to control the amount
that the wastegate opens. As the air pressure supplied
A Connector B
by the control valve to the wastegate valve increases,
B Junction points the valve opens wider. When the wastegate valve is
C Wastegate fully open, the exhaust gas flow to the exhaust turbine
is at its lowest.
b
The control valve is current controlled by the engine
control valve, using a PWM signal. As the current sup-
a plied to the control valve increases, the boost air pres-
(+) 57 R / BL
2 sure increases. The boost air pressure is constantly
(+) 60 R / BL monitored by a sensor installed in the inlet manifold.
1
GN
38
EMS
P0007253
TAD1340-1345VE, TAD1341-1345GE, TAD1350-55GE

a Wastegate
b Connector B
Measurements
Checking negative cable, wastegate valve page 178
Checking supply cable, wastegate valve page 179
Checking the wastegate valve page 180
126 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
MID 128, SID 70 Air inlet heater

driver #1

Fault code explanation: Faulty relay / Faulty relay circuit
CIU: None.
Flash code
Value fault: None.
Symptom: Fuse for shorting wire breaks.
Possible reason: • Short circuit to battery voltage in sense wire.
• Heating element broken.
Suitable action: 1 Check all cable and connections to heating element.
2 Check function of preheat relay.
3 Check heating element.

CIU: None.
Flash code
Value fault: None.
Symptom: Start problems in cold climate.
Possible reason: Short circuit to battery negative in sense wire.
Suitable action: 1 Check function of preheat relay.
2 Check all cable and connections to heating element.
47701632 10-2012 © AB VOLVO PENTA 127

30-2 Fault Tracing

CIU: None.
Flash code
Value fault: None.
Symptom: Might get start problems in cold climate.
Possible reason: • Preheater fuse broken.
• An open circuit in sense wiring.
• Heating element broken.
Suitable action: 1 Check preheater fuse.
2 Check contact pressure in socket 7 in engine connector B.
3 Check all cable and connections to heating element.
4 Check heating element.
Circuit description
OR In cold climate the intake air might need too be pre-
34
(+)57,60 R / BL heated. This is done by the preheater located on the
7 BN intake manifold. A sense wire is connected between
B C the preheater relay output and B7. The sense wire
checks that the preheat element and the preheat fuse
A EMS2 are not damaged. The activation of the preheater is
P0013533 controlled by the EMS2 via the preheat relay. EMS2
pin B25 activates the preheat relay.
A Connector B
B Junction point
C Preheat relay
Preheater fuse is located between preheat relay and

heating element.
P0013532
Measurements
Checking preheater relay page 181
128 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
MID 128, SID 211 Sensor Supply

Voltage #2 (+5V DC)

Fault code explanation: Fault in circuit.
CIU: Flash code
Flash code
Value fault: None.
Symptom: None.
Conditions for fault code: Abnormally high voltage or short circuit to higher voltage on pin B17.
Possible reason: Short circuit to battery voltage.
Suitable action: 1 Check the supply voltage to the sensors which have set fault codes.
2 Check sensor cables.
3 Check the sensors.

CIU: Flash code
Flash code
Value fault: None.
Symptom: None.
Conditions for fault code: Abnormally low voltage or short circuit to battery negative has on pin B17.
Possible reason: • Short circuit sensor supply voltage cable to battery negative, fuel pres-
sure sensor.
• Short circuit sensor supply voltage cable to battery negative, crankcase
sensor.
Suitable action: 1 Check the supply voltage to the above-mentioned sensors.
Circuit description
Pin B17 on the EMS2 distributes 5 Volt supply voltage
to the crankcase pressure sensor and the fuel pressure
sensor.
47701632 10-2012 © AB VOLVO PENTA 129

30-2 Fault Tracing
MID 128 / 144, SID 231 SAE J1939

data link

Fault code explanation: Communication fault J1939
CIU: Flash code
Flash code

Symptom: Engine can not be started or if engine is running it can only be stopped by
pushing the aux-stop.
Instruments and warning lamps stop working.
Conditions for fault code: CAN communication is missing.
Possible reason: • CAN H and CAN L short circuited to eachother.
• CAN H or CAN L short circuited to battery negative 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 EMS2.
B.
3 Check that the socket 11 and 12 in the CIU connector is undamaged.
Circuit description
A CAN H – Engine connector

A Y/W 1
B GR/Y 2 B CAN L – Engine connector
C SB 3
R 4 C Power supply, 0 V
D
E R/BL 5 D Power supply, input
F GR/SB 6
G W 7 E Ignition
H W/SB 8 F Stop
EMS2 a DCU/CIU G J1708A – Engine connector
P0013534
H J1708B – Engine connector
a Engine connector
Measurements
Checking CAN bus cable page 181
130 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
MID 128, SID 232 5 V supply

CIU: Flash code
Flash code
Value fault: None.
Symptom: None.
Conditions for fault code: Abnormally high voltage or short circuit to higher voltage on pin A7.
Possible reason: Short circuit to battery voltage.
Suitable action: 1 Check the supply voltage to the sensors which have set fault codes.

CIU: Flash code
Flash code
Value fault: None.
Symptom: None.
Conditions for fault code: Abnormally low voltage or short circuit to battery negative on pin A7.
Possible reason: • Short circuit sensor supply voltage cable to battery negative, oil pres-
sure sensor.
• Short circuit sensor supply voltage cable to battery negative, air inlet
pressure sensor.
Suitable action: 1 Check the supply voltage to the above-mentioned sensors.
Circuit description
Pin A7 on the EMS2 distributes 5 Volt supply voltage
to the oil pressure sensor and the air inlet pressure
sensor.
47701632 10-2012 © AB VOLVO PENTA 131

30-2 Fault Tracing
MID 128, SID 240 Program memory
FMI 11 – Unidentifiable error
FMI 14 – Special instructions

CIU: Flash code
Flash code
Value fault: None.
Symptom: Engine might not start.
Conditions for fault code: Signal value is irregular, intermittent or incorrect. Data communication inter-
rupted.
Possible reason: Memory fault in the EMS2.
Suitable action: 1 Reprogram the EMS2.
2 Change the EMS2.
132 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
MID 128, SID 250 SAE J1708/J1587

data link

Fault code explanation: Communication fault J1587/J1708
CIU: Flash code
Flash code
Value fault: None.
Symptom: None.
Conditions for fault code: Faulty data link.
Suitable action: 1 Check all data links between DCU/CIU and EMS2.
3 Check that the socket 22 and 37 in the CIU connector is undamaged.
Circuit description
A CAN H – Data Link to Engine

A Y/W 1
B GR/Y 2 B CAN L – Data Link to Engine
C SB 3
R 4 C Power supply, 0 V
D
E R/BL 5 D Power supply, input
F GR/SB 6
G W 7 E Ignition
H W/SB 8 F Stop
EMS2 a DCU/CIU G J1708A – Data Link to Engine
P0013534
H J1708B – Data Link to Engine
a Engine connector
47701632 10-2012 © AB VOLVO PENTA 133

30-2 Fault Tracing
MID 128 / 144, SID 253 Calibration

memory EEPROM
FMI 14 – Special instructions

CIU: Flash code
Flash code

Symptom: Engine does not start.
Possible reason: • Internal fault in control unit.
• Program fault.
Suitable action: 1 Reprogram the unit which set the faultcode.
2 Change the unit which set the faultcode.
134 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
MID 128 / 144, SID 254 Controller 1

Fault indication: CIU: Flash code
Flash code

Possible reason: • If faultcode MID 144, SID 254, FMI 11 appears the CIU throttle positive
and negative supply wire could be short circuited to eachother.
• Faulty EEPROM, CIU.
• Faulty flash memory, CIU.
• Fault in control unit, CIU.
Suitable action: 1 Check for short circuit in the supply cables to the CIU throttle potenti-
ometer.
2 Reprogram the unit which set the faultcode.
47701632 10-2012 © AB VOLVO PENTA 135

30-2 Fault Tracing
MID 128, PSID 201 Data link, MID144
FMI 9– Abnormal update rate

Fault code explanation: Communication error.
CIU: None.
Flash code
Value fault: None.
Symptom: None.
Conditions for fault code: No communication with the engine control unit.
Possible reason: • An open circuit in CAN H or CAN L or both CAN links between EMS 2
and DCU/CIU.
• An open circuit in Power supply 0V cable between EMS 2 and DCU/
CIU.
• An open circuit in Power supply input cable between EMS 2 and DCU/
CIU.
• CAN H short circuited to power supply in pin 4.
Suitable action: 1 Check contact pressure in socket 51 and 55 in engine connector B.
2 Check for an open circuit or short circuit between cables in the cable
harness between the DCU/CIU and EMS 2, via the engine connector.
Circuit description
A CAN H – Data Link to Engine

A Y/W 1
B GR/Y 2 B CAN L – Data Link to Engine
C SB 3
R 4 C Power supply negative
D
E R/BL 5 D Power supply positive
F GR/SB 6
G W 7 E Ignition
H W/SB 8 F Stop
EMS2 a DCU/CIU G J1708A – Data Link to Engine
P0013534
H J1708B – Data Link to Engine
a A27 Engine connector
Measurements
Checking the CAN bus cable page 183
136 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
No fault code
Fuel bleeding pump (only TAD950–952VE)

Symptom: Fuel bleeding pump doesn’t start when the fuel press switch is activated.
Possible reason: • Open circuit in any of the cables to the pump motor.
• Faulty fuel press switch.
• Faulty pump motor.
Suitable action: 1 Check the cables to the pump motor.
2 Check the fuel press switch.
3 Try another pump motor.
Circuit description
2 The fuel system has a fuel bleeding pump that is used
Conn. B
4 when the fuel system has to be bled. A manual fuel
R press switch is situated on the left side of the engine.
(+) 17 4 1
a When the fuel press switch is activated the fuel bleed-
SB
(-) 18 P ing pump starts to pump round the fuel.
2
GN / BL
16 3
SB
d 5
EMS2 R / BL
1 P b
c
P0014009
a Fuel pressure
b Fuel bleeding pump (P)
c Start
d Fuel press switch
47701632 10-2012 © AB VOLVO PENTA 137

30-2 Fault Tracing
Measurements
Checking the wiring
Tools:
88890074 Multimeter

2 Remove the wire to be measured from the preheat
relay.
3 Remove connector B from the EMS2.
4 Use multimeter 9812519 to do a resistance meas-
urement between connector B (see circuit descrip-
tion) to the loosen wire.
R ≈ 0Ω.
Checking supply cable, fuel sensor

Tools:
88890074 Multimeter
1 NOTICE! Turn ignition off.

2 Disconnect the connector from the sensor.
3 TAD1250-1252 and TWD1643/TWD1663/
TWG1663GE:
Connect adapter cable 885675 to the cable har-
ness connector to the engine control unit.
TAD950-952 (with bleeding pump):
4 Use multimeter 88890074 for voltage measure-
ment.
5 Turn ignition on.
Measurement points Nominal value

1 – 4 (no fuel bleeding pump) U≈5V
p0013473
2 – 4 (with fuel bleeding pump) U≈5V
138 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking negative cable, fuel

sensor
Tools:
88890074 Multimeter

3 TAD1250-1252 and TWD1643/TWD1663/
TWG1663GE:
TAD950-952:
4 Use multimeter 88890074 to do resistance meas-
urement against the engine control unit.

4 – Battery negative R≈0Ω
(no fuel bleeding pump)
885675 4 – Battery negative R≈0Ω
(with fuel bleeding pump)
p0013474
NOTICE! Measurement is done to eliminate short cir-

cuiting or breaks in the cable to the engine control unit.
47701632 10-2012 © AB VOLVO PENTA 139

30-2 Fault Tracing
Checking the signal cable for

interruption or shortcircuit
Tools:
88890074 Multimeter

3 TAD1250-1252 and TWD1643/TWD1663/
TWG1663GE:
TAD950-952:
4 Remove connector B from the engine control unit.
urement against the engine control unit connector
B.

2(885675)– 16(EMS2, conn.B) R≈0Ω
885 675 (no fuel bleeding pump)
2(885675)– 18(EMS2, conn.B) R≈∞Ω
2(885675)– 17(EMS2, conn.B) R≈∞Ω
3(88890053) – 16(EMS2, R≈0Ω
conn.B)
3(88890053) – 18(EMS2, R≈∞Ω
conn.B)
3(88890053) – 17(EMS2, R≈∞Ω
conn.B)

p0013475
IMPORTANT!
Be very careful when measuring inside the connector,
to ensure that no pin is damaged.
140 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking fuel pressure sensor

V Tools:
88890074 Multimeter

3 TAD1250-1252 and TWD1643/TWD1663/
TWG1663GE:
Connect adapter cable 885675 between the sensor
and the engine control unit.
TAD950-952:
Connect adapter cable 88890053 between the sen-
sor and the engine control unit.
ment.
5 Turn ignition on.

88 5675 4–3 U ≈ 0,5 V
5
(no fuel bleeding pump) (at normal atmos-

4
3
2
4 pheric pressure)
1
3
p0013476
4–3 U ≈ 0,5 V
(with fuel bleeding pump) (at normal atmos-
pheric pressure)
47701632 10-2012 © AB VOLVO PENTA 141

30-2 Fault Tracing
Checking supply cable, water in fuel

switch
Tools:
88890074 Multimeter

2 Disconnect the connector from the switch.
V
3 Use multimeter 88890074 to do voltage measure-
ment towards the engine control unit.
4 NOTICE! Turn ignition on.

Yellow conductor – U ≈ Battery voltage x 0.8
Black conductor
p0013376
142 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking negative cable, water in

fuel switch
Tools:
88890074 Multimeter


Black conductor – R≈0Ω
Battery negative
P0013419
Checking water in fuel switch

Tools:
9998699 Break-out box
88890074 Multimeter

2 Connect break-out cable 9990014 with break-out
box 9998699 between EMS 2 (connector B) and the
switch.
ment.
4 Turn ignition on.

10 - 8 Switch immersed in U ≈ 0,8 x battery voltage
fuel
10 - 8 Switch immersed in U ≈ 0,8 x battery voltage -
water 5V
47701632 10-2012 © AB VOLVO PENTA 143

30-2 Fault Tracing
Checking oil level sensor

Tools:
Tools:
88890074 Multimeter

2 Connect break-out cable (885675) to the sensor.
Do not connect the other end of the adapter cable.
urement.

1–2 R ≈ 10 – 14 Ω
NOTICE! Even if the nominal value is correct the sen-

sor could be faulty.
75
8856
5
4
3
2
1
2
P0013296
1
Checking supply cable, oil pressure

sensor
Tools:
88890074 Multimeter

2 Remove the connector from the sensor. Connect
break-out cable 885675 between the sensor and
engine control unit.
ment.

1–4 U≈5V
P0001355
144 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking negative cable, oil

pressure sensor
Tools:
88890074 Multimeter

3 Connect break-out cable 885675 to the cable har-

4 885675
P0013657
Checking signal cable, oil pressure

sensor
Tools:
88890074 Multimeter


2–4 R ≈ 80 – 120 kΩ

P0001266
47701632 10-2012 © AB VOLVO PENTA 145

30-2 Fault Tracing
Checking oil pressure sensor

Tools:
88890074 Multimeter

3 Connect break-out cable 885675 between the sen-
ment.
5 Turn ignition on.

2–4 U ≈ 0,5 V (at normal
atmospheric pressure)
P0013482
146 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking signal cable voltage, inlet

manifold (pressure/)temperature
sensor
V
Tools:
88890074 Multimeter

ment.
5 Turn ignition on.
75
8856
5
V
4
885675
3
2
1
1
2 1–2 U≈5V
1 Turn ignition off.

3 Turn ignition on.

1–2 U ≈ 0.5– 4.5 V (depended
of the temperature)
75
8856 885675
5
4
3
2
1
2
P0013483 1
47701632 10-2012 © AB VOLVO PENTA 147

30-2 Fault Tracing
Checking negative cable, inlet

manifold pressure/temperature
sensor
Tools:
88890074 Multimeter


885675
P0013484 1
148 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking the sensor cable for open

circuit or shortcircuit
Inlet manifold temperature sensor
Tools:
88890074 Multimeter

4 Remove connector A from the engine control unit.
urement against engine control unit connector A.

2 (885675)– 47(EMS2, conn.A) R≈0Ω
2 (885675)– 11(EMS2, conn.A) R≈∞Ω
1 (885675)– 47(EMS2, conn.A) R≈∞Ω
1 (885675)– 11(EMS2, conn.A) R≈0Ω

IMPORTANT!
P0013485
47701632 10-2012 © AB VOLVO PENTA 149

30-2 Fault Tracing
Checking inlet manifold

temperature sensor
Tools:
88890074 Multimeter

urement.

1–2 R ≈ 9426 Ω
+/- 470 Ω (vid -10° C)
1–2 R ≈ 5896 Ω
+/- 332 Ω (vid 0° C)
1–2 R ≈ 2511 Ω
+/- 109 Ω (vid 20° C)
1–2 R ≈ 1200 Ω
75 +/- 47 Ω (vid 40° C)
8856 885675
5
1–2 R ≈ 612 Ω
4
3
2
+/- 22 Ω (vid 60° C)
1
2
P0013486 1 1–2 R ≈ 329 Ω
+/- 11 Ω (vid 80° C)
1–2 R ≈ 186 Ω
+/- 5 Ω (vid 100° C)
1–2 R ≈ 110 Ω
Checking supply cable, inlet

manifold pressure sensor
V Tools:
88890074 Multimeter

ment.
4 Turn ignition on.

1–3 U≈5V
75
8856
5
4
3
2
1
3
1
P0013487
150 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking signal cable, inlet

manifold pressure sensor
Tools:
88890074 Multimeter


4–1 R ≈ 80 – 120 k Ω
75
8856
885675 cuiting or breaks in the cable to the engine control unit.
5
4
3
2
4
1
P0013488 1
Checking air inlet pressure sensor

Tools:
88890074 Multimeter

ment.
5 Turn ignition on.
Measurement Nominal value

points
1–4 U ≈ 1,1 V (at normal
4
P0013489
1
47701632 10-2012 © AB VOLVO PENTA 151

30-2 Fault Tracing
Checking supply cable, air filter

pressure switch
Tools:
88890074 Multimeter

3 Connect break-out cable 885675 between the
switch and engine control unit.
ment.

1–2 U ≈ 2.9 V

2
1
P0013494 1–2 U ≈ 0.8 x battery voltage
Checking air pressure switch

Tools:
88890074 Multimeter

3 Connect break-out cable 885675 to the switch.
4 Use multimeter 88890074 for resistance measure-
ment.

1–2 R ≈ 330 Ω
75 NOTICE! If the measured value is 2.2 kOhm when the

8856
engine is shut down the switch inside is stuck in active
5
4
3
2
885675 position.
1
2
P0013496
1
152 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking coolant temperature

sensor
Tools:
88890074 Multimeter

2 Connect adapter cable (885675) to the sensor.
urement.

1–2 R ≈ 9397 Ω
+/- 755 Ω (at -10° C)
1–2 R ≈ 5896 Ω
+/- 430 Ω (at 0° C)
1–2 R ≈ 2500 Ω
8856
75 +/- 148 Ω (at 20° C)
5
4
1–2 R ≈ 1175 Ω
3
2
885 675
1
P0004935 1 2
+/- 56 Ω (at 40° C)
1–2 R ≈ 596 Ω
+/- 22 Ω (at 60° C)
1–2 R ≈ 323 Ω
+/- 10 Ω (at 80° C)
1–2 R ≈ 186 Ω
+/- 5 Ω (at 100° C)
1–2 R ≈ 113 Ω
47701632 10-2012 © AB VOLVO PENTA 153

30-2 Fault Tracing

Coolant temperature sensor
Tools:
88890074 Multimeter

B.
75
B 2 (885675)– 27 (EMS2, conn.B) R≈0Ω
8856
885675
5
2 (885675)– 18 (EMS2, conn.B) R≈∞Ω

4
3
2
1
2 1 (885675)– 27 (EMS2, conn.B) R≈∞Ω

1 (885675)– 18 (EMS2, conn.B) R≈0Ω

4
8
1
5
IMPORTANT!
9
16 13
20 17 to ensure that no pin is damaged.
24 21
28 25
40 37
44 41
75
8856
48
5
45
4
52 49
3
2
56 53
1
1
52 60
P0004936 B
154 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking supply cable, coolant

level switch
Tools:
88890074 Multimeter

ment.

1–2 U ≈ Battery voltage x 0.8
Checking negative cable, coolant

level switch
Tools:
88890074 Multimeter


2 – Battery negative R≈ 0 Ω
Checking coolant level switch

Tools:
88890074 Multimeter
NOTICE! The coolant level switch can be removed

without having to drain the coolant.
47701632 10-2012 © AB VOLVO PENTA 155

30-2 Fault Tracing
1 Undo the connector and remove the switch from the

expansion tank.
urement against the switch.
Blue – Black R≈∞Ω
3 Move a magnet along the switch and observe the

resistance value. The resistance should drop to
approx. 0 Ohm.

Blue – Black R≈0Ω
Checking crankcase pressure

sensor
Tools:
88890074 Multimeter

ment.
5 Turn ignition on.

2–4 U ≈ 2.9 V (at normal
P0001265
156 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking signal cable, air filter

temperature switch
Tools:
88890074 Multimeter

ment.

3–4 U≈5V
75
8856
5
4
3
2
4
1
3
P0013499

3 Turn ignition on.

3–4 U ≈ 0.5 – 4.5 V (depended
of the temperature)
75
8856
5
4
3
2
4
1
3
P0013500
47701632 10-2012 © AB VOLVO PENTA 157

30-2 Fault Tracing
Checking negative cable, air filter

temperature switch
Tools:
88890074 Multimeter


3 — Battery negative R≈0Ω
75
8856
5
4
3
2
1
3
P0013501
158 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing

Air filter temperature sensor
Tools:
88890074 Multimeter

B.

B
4 (885675) – 31(EMS2, conn.B) R≈0Ω
75
8856
4 (885675) – 18(EMS2, conn.B) R≈∞Ω
5
4
3
2
4 3 (885675) – 31(EMS2, conn.B) R≈∞Ω
1
885 675 3 (885675) – 18(EMS2, conn.B) R≈0Ω

4
8
1
5
IMPORTANT!
9
16 13 Be very careful when measuring inside the connector,
20 17
24 21
28 25
40 37
44 41
48 45
75 52 49
8856 56 53
5
4
3
2
1
3
52 60
P0013502 B
47701632 10-2012 © AB VOLVO PENTA 159

30-2 Fault Tracing
Checking air inlet temperature

sensor
Tools:
88890074 Multimeter

2 Connect adapter cable (885675) to the sensor.
urement.

3–4 R ≈ 16445 Ω
+/- 822 Ω (at 0°C)
3–4 R ≈ 5000 Ω
+/- 220 Ω (at 25°C)
3–4 R ≈ 4027 Ω
+/- 160 Ω (at 30°C)
3–4 R ≈ 1247 Ω
8856
75 +/- 40 Ω (at 60°C)
5
4
3–4 R ≈ 463 Ω
3
2
4 885 675 +/- 19 Ω (at 90°C)
1
3
P0013503 3–4 R ≈ 199 Ω
+/- 10 Ω (at 120°C)
Checking signal cable, exhaust gas

temperature sensor
Tools:
88890074 Multimeter

2 Remove the connector from the sensor.
ment.

1–2 U≈5V
160 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking negative cable, exhaust

gas temperature sensor
Tools:
88890074 Multimeter


1 — Battery negative R≈0Ω
Checking exhaust gas temperature

sensor
Tools:
88890074 Multimeter

2 Remove the connector from the sensor and remove
the sensor from exhaust bend to check that the
sensor has no visible damage.
3 Use multimeter 88890074 to measure resistance
between the two contact pins on the sensor. The
resistance shall agree with the values in the chart.
Measurement Nominal Nominal voltage

value points resistance value measured over
the sensor
1–2 R ≈ 185 Ω U ≈ 0.78 V
at -20° C at -20° C
1–2 R ≈ 200 Ω U ≈ 0.84 V
at 0° C at 0° C
1–2 R ≈ 220 Ω U ≈ 0.90 V
at 25° C at 25° C
1–2 R ≈ 238 Ω U ≈ 0.96 V
at 50° C at 50° C
1–2 R ≈ 276 Ω U ≈ 1.08 V
at 100° C at 100° C
1–2 R ≈ 313 Ω U ≈ 1.19 V
at 150° C at 150° C
1–2 R ≈ 349 Ω U ≈ 1.29 V
at 200° C at 200° C
1–2 R ≈ 385 Ω U ≈ 1.39 V
at 250° C at 250° C
1–2 R ≈ 420 Ω U ≈ 1.48 V
at 300° C at 300° C
47701632 10-2012 © AB VOLVO PENTA 161

30-2 Fault Tracing
1–2 R ≈ 454 Ω U ≈ 1.56 V

at 350° C at 350° C
1–2 R ≈ 488 Ω U ≈ 1.64 V
at 400° C at 400° C
1–2 R ≈ 521 Ω U ≈ 1.71 V
at 450° C at 450° C
1–2 R ≈ 554 Ω U ≈ 1.78 V
at 500° C at 500° C
1–2 R ≈ 618 Ω U ≈ 1.91 V
at 600° C at 600° C
1–2 R ≈ 679 Ω U ≈ 2.02 V
at 700° C at 700° C
1–2 R ≈ 738 Ω U ≈ 2.12 V
at 800° C at 800° C
1–2 R ≈ 795 Ω U ≈ 2.21 V
at 900° C at 900° C
1–2 R ≈ 849 Ω U ≈ 2.30 V
at 1000° C at 1000° C
Checking negative cable, oil

temperature switch
Tools:
88890074 Multimeter


75
8856
5
4
3
2
4
1
P0013506
162 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking signal cable, oil

temperature switch
Tools:
88890074 Multimeter

V
ment.
5 Turn ignition on.

3–4 U≈5V

V 2 Connect break-out cable 885675 between the sen-
8856
75
5
4
3
2
4
3 Turn ignition on.
1

3–4 U ≈ 0.5-4.5 V (depended
of the temperature)
75
8856
5
4
3
2
4
1
3
P0013507
47701632 10-2012 © AB VOLVO PENTA 163

30-2 Fault Tracing
Checking oil temperature sensor

Tools:
88890074 Multimeter

urement.

3–4 R ≈ 4981 Ω
+/- 503 Ω (at 0°C)
3–4 R ≈ 1900 Ω
+/- 163 Ω (at 20°C)
3–4 R ≈ 809 Ω
+/- 59 Ω (at 40°C)
3–4 R ≈ 378 Ω
+/- 24 Ω (at 60°C)
3–4 R ≈ 191 Ω
+/- 10 Ω (at 80°C)
3–4 R ≈ 104 Ω
+/- 5 Ω (at 100°C)
3–4 R ≈ 60 Ω
+/- 3 Ω (at 120°C )
P0013508
Checking starter motor relay

Tools:
88890074 Multimeter
1 NOTICE! Turn off the main switch.

2 Undo the red/yellow cable on the startermotor.
urement towards the relay.
Nominal value
R ≈ 8 – 14 Ω
P0013509
164 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking negative cable, air filter

pressure switch
Tools:
88890074 Multimeter


75
8856
5
4
3
2
1
1
P0013495
Checking stop signal cable between

ECU and CIU/DCU
V Tools:
88890074 Multimeter

2 Connect adapter cable 88890016 with measurebox
9998699 between the engine and the CIU/DCU.
Use the engine connector.
ment.
4 Turn ignition on.
Measurement points in Nominal value

measurebox
18 – 21 (energized to stop) U ≈ 0,8 x battery voltage
18 – 21 (energized to run) U ≈ Battery voltage
9
869
999 7
6
14
5
13
4 21
12
3 20
11 28
2 19
10 27
1 18 35
9 26
17 34
8 25 42
16 33
24 41
15 32 49
23 40
31 48
22 39 56
30 47
38 55
29 46
37 54
45 62
36 53
44 61
52
43 60
51
59
50
58
57
P0013510
47701632 10-2012 © AB VOLVO PENTA 165

30-2 Fault Tracing
Checking signal cable, coolant

temperature switch
V Tools:
88890074 Multimeter

ment.

75
8856
1–2 U≈5V
5
4
3
2
1
1 2 V 1 Turn ignition off.

885 675
3 Turn ignition on.

1–2 U ≈ 0.5 – 4.5 V (depended
of the temperature)
75
8856
5
4
3
2
1
1 2
P0004938 885 675
166 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking negative cable, coolant

temperature switch
Tools:
88890074 Multimeter


75
8856
885675
5
4
3
2
1
1
P0004937
Checking negative cable, piston

cooling oil temperature switch
Tools:
88890074 Multimeter

2 Undo the connector from the switch. Connect the
adapter cable (9998534) to the cable harness con-
nector that is connected to the engine control unit.
3 Use the multimeter (88890074) to do resistance
measurement against the engine control unit.

75
8856
5
4
3
2
885675
1
2
P0013512
47701632 10-2012 © AB VOLVO PENTA 167

30-2 Fault Tracing
Checking supply cable, piston

cooling oil temperature switch
Tools:
88890074 Multimeter
1 NOTICE! Turn the starter key to the stop position.

2 Undo the connector from the switch. Connect the
adapter cable (9998534) to the cable harness con-
nector that is connected to the engine control unit.
3 Use multimeter (88890074) for voltage measure-
ment.
4 Turn the starter key to position I (drive position).

1–2 U ≈ 0.8 x Battery voltage
7 5
8856
5
4
3
2
885675
1
2
1
P0013513
Checking IEGR coil

Tools:
88890074 Multimeter

box 9998699 between EMS 2 (connector B) and the
IEGR.
3 Use multimeter 88890074 to measure the resist-
ance in the IEGR coil and cable harness.

30 – 60 R ≈ 33 – 49 Ω
168 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking IEGR solenoid

2 Remove the IEGR solenoid. Please see workshop
manual Group 21-26 for reference how to remove
the IEGR solenoid.
3 One part of the solenoid is spring loaded. Press
gently down that part with a screwdriver and hold.
4 Connect a 24 volt power supply to the IEGR elec-
trical connection. The solenoid should now make a
click when alter its position and one should feel a
pressure in the screwdriver.
LTS
VO
P0013517
47701632 10-2012 © AB VOLVO PENTA 169

30-2 Fault Tracing
Checking supply cable, coldstart

valve
Tools:
88890074 Multimeter

2 Remove the connector from the valve. Connect
break-out cable 885675 between the valve and
ment.
4 Turn ignition on.

1 - 4 (valve activated) U ≈ battery voltage
1 - 4 (valve not activated) U ≈ 0V
P0013521
170 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking negative cable, coldstart

valve
Tools:
88890074 Multimeter

2 Disconnect the connector from the valve.
3 Connect break-out cable 885675 to the valve.
urement.

Also do a continuity test between 1 - 4 to verify that the

coil inside the valve is intact.
P0013522
47701632 10-2012 © AB VOLVO PENTA 171

30-2 Fault Tracing
Trimming the injector

The electronic trim strategy is used to ensure that all
injectors run with nominal timing and fuel delivery. This
is achieved by adjusting the beginning and end of the
electronic drive waveform for each actuator to com-
pensate for spread in actuation and deactuation times
of the two actuators in each injectors and to correct for
variations in fuelling due to nozzle flow variations.
NOTICE! Write down the new injector’s code before

installation. The code consists of 9 characters and is
on the injector’s electric connector under the SN num-
ber.
1 Connect Vodia and switch on the current for the

engine.
2 Go into the ”Service and maintenance” menu in
Vodia.
3 Select ”Parameter, programming”.
4 Press ”Play”.
5 Select the cylinder number corresponding to the
injector which has been changed.
6 Enter the new injector’s code. Click ”OK”.
7 Close ”Parameter, programming”.
8 Vodia will ask you to ”Turn off the main switch”, then
follow the instructions.
9 Report the parameters back as in items 10 - 13
in ”Programming the control unit”.
172 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking the injector wiring

Tools:
88890074 Multimeter
1 NOTICE! Turn the starter key to the stop position.

4 1
8 5
2 Turn the main switch off.
9
16 13 IMPORTANT!
20 17
The system must be disconnected from system voltage
24 21
28 25 and the starter key must be in position 0 when the engine
control unit connector is disconnected or connected.
40
44
37 3 Remove the connector from the engine control unit.
41
48
Move the lock catch (1) upwards and pull the con-
45
52
56
49 nector (2) out.
53
4 Use multimeter 88890074 to measure the resist-
A ance in the engine cable’s black (upper) connector
52 60
for the injectors.
A IMPORTANT!
P0013524
NOTICE! The measurement should exclude short cir-

cuiting or open circuit in the cable to the injector.

in connector A
20 – 62 Cylinder 1 R ≈ 1.4 – 3 Ω
( at 20° C )
12 – 62 Cylinder 2 R ≈ 1.4 – 3 Ω
( at 20° C )
28 – 62 Cylinder 3 R ≈ 1.4 – 3 Ω
( at 20° C )
24 – 59 Cylinder 1 R ≈ 1.4 – 3 Ω
(at 20° C )
16 – 59 Cylinder 2 R ≈ 1.4 – 3 Ω
( at 20° C )
32 – 59 Cylinder 3 R ≈ 1.4 – 3 Ω
( at 20° C )
52 – 61 Cylinder 4 R ≈ 1.4 – 3 Ω
( at 20° C )
44 – 61 Cylinder 5 R ≈ 1.4 – 3 Ω
( at 20° C )
36 – 61 Cylinder 6 R ≈ 1.4 – 3 Ω
( at 20° C )
56 – 60 Cylinder 4 R ≈ 1.4 – 3 Ω
( at 20° C )
48 – 60 Cylinder 5 R ≈ 1.4 – 3 Ω
( at 20° C )
40 – 60 Cylinder 6 R ≈ 1.4 – 3 Ω
(at 20° C )
47701632 10-2012 © AB VOLVO PENTA 173

30-2 Fault Tracing
Checking IEGR wiring

2 Remove the valve cover.
3 Remove the connector from the IEGR solenoid.
urement between connector B from the EMS2 to
the loosend connector.

B30 – 1 (IEGR connector) R ≈ 0 Ω
B30 – 2 (IEGR connector) R ≈ ∞ Ω
IMPORTANT!
Checking camshaft sensor wiring

Tools:
88890074 Multimeter

break-out cable 885675 to the connector.
3 Remove connector A from the EMS2.
urement from the sensor connector to connector A
to verify that neither of the wires are broken or short
circuited.
B
75
8856
Measurement points Nominal
5
4
3
2
value
1
2
885675 1 1 (sensor conn.) – 38 (conn. A) R≈0Ω
2 (sensor conn.) – 37 (conn. A) R≈0Ω
1 (sensor conn.) – 2 (sensor conn.) R≈∞Ω
4 1
8 5
9
16
20
13
17
IMPORTANT!
24
28
21
25
40 37
44 41
48 45
52 49
56 53
75
8856
5
4
3
2
52 60
1
2
B
P0013526
174 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking camshaft sensor

Tools:
88890074 Multimeter

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.
3 Connect break-out cable 885675 to sensor.
75
NOTICE! Do not connect the other end of the
8856
adapter cable to the engine cable harness, since
5
4
3
2
V this can cause a measurement error.
1
2
1
885 675 4 Use multimeter 88890074 for resistance measure-
ment.
1–2 R ≈ 0,9 kΩ at 20°C
5 Use multimeter 88890074 for a AC voltage meas-

urement.
Move a metal object rapidly back and forwards not
75
more than 1 mm in front of the sensor. Check that
8856
the multimeter gives a reading.
5
4
3
2
1
1
2 6 Install the sensor.
885 675
P0008931
47701632 10-2012 © AB VOLVO PENTA 175

30-2 Fault Tracing
Checking flywheel sensor wiring

Tools:
88890074 Multimeter

break-out cable 885675 to the connector.
3 Remove connector A from the EMS2.
urement from the sensor connector to connector A
to verify that neither of the wires are broken or short
B
circuited.
75
8856
5
4
Measurement points Nominal

3
2
1
2 value
885675 1
4 1
8 5
9
1 (sensor conn.) – 2 (sensor conn.) R≈∞Ω
16 13
20 17
24
28
21
25
IMPORTANT!
40
37
44
48
41
45
52 49
56 53
75
8856
5
4
3
2
52 60
1
2
P0013527
B
176 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking flywheel sensor

Tools:
88890074 Multimeter

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.
3 Connect break-out cable 885675 to sensor.
75
8856
5
4
3
2
V this can cause a measurement error.
1
2
1
885 675 4 Use multimeter 88890074 for resistance measure-
ment.
1–2 R ≈ 0,9 kΩ at 20°C
5 Use multimeter 88890074 for a AC voltage meas-

urement.
Move a metal object rapidly back and forwards not
75
more than 1 mm in front of the sensor. Check that
8856
the multimeter gives a reading.
5
4
3
2
1
1
2 6 Install the sensor.
885 675
P0008931
47701632 10-2012 © AB VOLVO PENTA 177

30-2 Fault Tracing
Checking negative cable, wastegate

valve
Tools:
88890074 Multimeter

2 Disconnect the connector from the wastegate reg-
ulator(1).
3 Connect break-out cable 88890053 to the cable
harness connector to the engine control unit.

7 – Battery negative(B-) R≈0Ω
178 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking supply cable, wastegate

valve
Tools:
88890074 Multimeter

2 Remove the connector from the wastegate regula-
tor.
3 Connect break-out cable 88890053 between the
wastegate regulator and engine control unit.
ment.

1–7 U ≈ Battery voltage
47701632 10-2012 © AB VOLVO PENTA 179

30-2 Fault Tracing
Checking the wastegate valve

Tools:
88890074 Multimeter

2 Remove the connector from the wastegate valve.
Connect break-out cable 885675 to the valve.
this can cause a measurement error.
3 Use multimeter 88890074 to check the resistance
in the wastegate valve.
NOTICE! Measurement is done to eliminate short
circuiting or breaks in the wastegate valve.

1–2 R = 90 ± 4.5 Ω
at 20 °C (68°F)
180 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking preheater relay

Tools:
88890074 Multimeter

3 Connect break-out cable 9990014 between con-
nector B and engine control unit.
ment.

B7 – B59 U≈0V
If there is an open circuit in the sense wiring circuit the

multimeter will show:
Measurement points Fault value

B7 – B59 U ≈ 19.5 V
Checking CAN bus cable

Tools:
88890074 Multimeter
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.
2 Disconnect the 8-pin Deutsch connector at the
DCU or disconnect at the CIU.
3 Connect break-out box 9998699 with break-out
cable 88890016 between the engine control unit
and the DCU.
urement towards the EMS 2.
8699
16–17 U ≈ 60 Ω
999 7
6
14
5
13
4 21
12
3 20
11 28
2 19
10 27
1 18 35
9 26
17 34
8 25 42
16 33
24 41
15 32 49
23 40
31 48
22 39 56
30 47
38 55
29 46
37 54
45 62
36 53
44 61
52
43 60
51
59
50
58
57
P0013535
47701632 10-2012 © AB VOLVO PENTA 181

30-2 Fault Tracing
or
29 15 1
in the CIU connector
11–12 U ≈ 60 Ω
NOTICE! Even if the measured value equals the nom-

11 inal value the data bus cable could be faulty due to
12
short circuit between a data bus cable and another
cable in the harness.
43 28 14
P0013536

box 9998699 between the EMS 2 and the CIU/
DCU.
2 Use multimeter 88890074 to do a voltage meas-
urement.
V
in the measurebox
16 (CAN-H) – U ≈ 2.3 V – 2.7 V
18 (power supply 0V)
17 (CAN-L) – U ≈ 2.3 V – 2.7 V
18(power supply 0V)

inal value the data bus cable could be faulty due to
9
869
999 7
6
14
5
13
4 21
12
3 20
11 28
2 19
10 27
1 18 35
9 26
17 34
8 25 42
16 33
24 41
15 32 49
23 40
31 48
22 39 56
30 47
38 55
29 46
37 54
45 62
36 53
44 61
52
43 60
51
59
50
58
57
P0013537
182 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking the CAN bus cable

Tools:
88890074 Multimeter
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.
2 Disconnect the 8-pin Deutsch connector at the
DCU or disconnect at the CIU.
urement towards the EMS 2.

in the engine connector
at the DCU
1–2 U ≈ 60 Ω
or

in the CIU connector
11–12 U ≈ 60 Ω


box 9998699 between the EMS 2 and the CIU/
DCU.
2 Use multimeter 88890074 to do a voltage meas-
urement.

in the measurebox
16 – 17 (between CAN U ≈ 2.3 V – 2.7 V
bus)

47701632 10-2012 © AB VOLVO PENTA 183

30-2 Fault Tracing
Checking negative cable, crankcase

pressure sensor
Tools:
88890074 Multimeter


P0001264
Checking signal cable, crankcase

pressure sensor
Tools:
88890074 Multimeter


2–4 R ≈ 80 -120 kΩ

P0001266
184 47701632 10-2012 © AB VOLVO PENTA

30-2 Fault Tracing
Checking supply cable, crankcase

pressure sensor
Tools:
88890074 Multimeter

ment.

1–4 U≈5V
P0001355
Vodia logging throttle signal

To verify the throttle signal on the J1587 bus do as fol-
low:
1 Choose “Log test” under the “Service and mainte-
nance” menu.
2 Choose “MID 128, Accelerator Pedal Position” and
“MID 144, Throttle Calibrated Position” and press
play.
3 Verify that booth throttle values displayed in per-
centage by Vodia changes simultaneous while
moving the throttle.
47701632 10-2012 © AB VOLVO PENTA 185

47701632 10-2012 © AB VOLVO PENTA
CAN BATT.+ 1708
J1939 BATT.- SWITCHED J1587
HL BATT.+ STOP AB
17 1 2 3 4 5 6 7 8
19
R/BL 1,5
1 2 3 4 5 6
GR/SB
SB 2,5
W/SB
GR/Y
R 2,5
Y/W
SB 1,5
15
W/SB
R 1,5
W
P 28
W
24 18 4 P2 21
1 2 1 20 1 2
4
CAN 2
SB Y 86
12 3 4 5 6 7 1 2 3 4 5 6 7 5 Y/SB
1
85
R/BL 1,5 87
2
23 R 1,5
4
30
SB R 1,5
7 25
3
SB 5
2
1 12 8 R/BL
R
1
SB SB 2
2P 4
11 P
1
3θ 4
1 2
R/BL 1,5
R/BL 1,5
GN/SB
BL/OR
BL/GR
GN/BL
SB 1,5
SB 1,5
SB 1,5
SB 1,5
SB 1,5
GN/W
GR/W
BL/W
GN/R
GR/Y
R 1,5
LBN
Y/W
R/Y
OR
Y
11 23 3 4 10 8 52 56 28 17 16 18 27 57 60 25 29 51 55 58 59 61
h l
6 CONNECTOR B
CONNECTOR A BA
22
37-0 Wiring Diagrams
7 22 47 11 31 45 46 37 38 40 48 56 32 16 24 59 60 8 33 34 27 58 57
GR/GN
- OR/SB
GR/SB
GR/SB
VO/SB
Y/SB
W/SB
GR/SB
R/BL 1,5
SB 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
SB 1,5
R 1,5
BN/OR
GR/OR
W
R SB
1234
1 2 3 4 CAPILLERING STOPPER x8
1234
1 2 3 4
27
CYL. 1 MAIN RELAY HOLD
9
TAD940-41GE, TAD940-43
R
1 θ3 16
CYL. 2
SB 1 234 1 234
2P 4
1 234 1 234
16 1
26
1
CYL. 3
SB 2,5
10
R 2,5
R/BL
R/Y
R
1 16 CYL. 4 123 4 5 50
2P 4 SB
16 B+
G
B-
31 M
CYL. 5 SB 16
1 2 1 2
16 3 R 16 2
CYL. 6
P0012802
n n
1
13 14 16
186
START
- +
1 Battery Cable colors

2 Starter motor BL = Blue P = Pink
BN = Brown R = Red
3 Alternator GN = Green SB = Black
4 Main relay GR = Gray VO = Violet
OR = Orange W = White
5 Stop switch LBL = Light blue Y = Yellow
6 Control unit EDC LBN = Light brown
7 Sensor, coolant level

Cable cross section = 0.75 mm2 unless otherwise
8 Sensor, coolant temperature stated.
9 Sensor, air inlet pressure / inlet manifold tem-
perature
10 Sensor, oil pressure
11 Sensor, oil level / oil temperature
12 Sensor, crankcase pressure
13 Sensor, camshaft
14 Sensor, flywheel
15 Sensor, fuel pressure
16 Unit injector (Cyl. 1-6)
17 Connector - engine interface
18 Connector - application tool
19 Connector - serial J1587
20 AUX STOP
21 Jumper - removeable
22 Fuse 10A
23 Switch - fuel pump
24 Switck - water in fuel
25 Connector - remote water in fuel
26 Pre-heater
27 Pre-heater relay
28 Fuel pump
47701632 10-2012 © AB VOLVO PENTA 187

47701632 10-2012 © AB VOLVO PENTA
11 16
H L 12 13 15 A B
CAN 2 14
(18) 1 2 17
6
9 1 2 3 4 5 6 7 8 12 3 4 5 6
W/SB
R/BL 1,5
VO/SB
GR/SB
GR/Y
R 2,5
4
SB 2,5
Y/W
P2
4
1
P 2 1
INTERNAL
SB Y EGR 19
12 3 4 5 6 7 CAPILLERING 18 86
1 1 2 3 4 5 67 10 Y/SB 85
STOPPER x2 1
(5) 87
2 SB (25)
R/BL 1,5 2
1 SOLENOID R 1,5 30
4
WIF 7 R 1,5 3
(23) SB 5
2
B SB
C (2)
(1) 5 8 R/BL
SB SB
4
(2) B
CAN j1939
2P (1)
CAN 2
1R C
3
3
4
1 2 R/BL 1,5
R/BL 1,5
GN 1,0
GN/SB
SB 1,5
SB 1,5
SB 1,5
GN/BL
SB 1,5
BL/OR
BL/GR
GN/W
SB1,5
GR/W
GR/R
GN/R
GR/Y
BL/W
R 1,5
LBN
Y/W
R/Y
OR
Y
11 14 23 3 4 10 8 28 17 16 18 27 52 56 30 57 60 58 59 61 51 55 25 29
B 31 h l h l
(6) 33
A 32 B A
R 2,5
7 11 47 22 31 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24 59 62 60 61 8 33 34 27 58 57
GR/SB
R/BL 1,5
R 1,5
GR/SB
GR/GN
W/SB
VO/SB
VO/SB
GR/SB
BN/OR
OR/SB
W 1,5
W 1,5
SB 1,5
Y/SB
W 1,5
W 1,5
GR/OR
SB 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
30 20
SB 1
R3 2
P4
BOOST TEMP CAPILLERING 123 4 21
& PRESS
STOPPERS X16
SB 4 29 MAIN RELAY HOLD
R1
P2 26 (27)
OIL PRESS 4 3
2 1 1
CYL. 1 1
SB 2,5
SB 16
R 2,5
26
R/BL
22
R/Y
25
CYL. 2 12 3 45 R 16
26 31 M
B+ G G B- SB 16 24
(3) (2)
R 16
28 27 CYL. 3
21 21 26 (1)
P0014016
n n
START
CAM CRANK
TAD950-952VE
Engine speed Engine speed CYL. 4

23
26
CYL. 5
26
4 3
188
2 1
CYL. 6
1 Switch, piston cooling Cable colors

2 Switch, coolant level BL = Blue P = Pink
BN = Brown R = Red
3 Sensor, oil temperature and oil level GN = Green SB = Black
4 Switch, water in fuel GR = Gray VO = Violet
5 Sensor, crankcase pressure LBL = Light blue Y = Yellow
6 Sensor, fuel pressure / fuel temp. LBN = Light brown
7 Switch for electric feed pump switch

9 Internal EGR
10 Extra stop
11 J1939 CAN (bus)
12 Battery negative
13 Battery plus
14 Voltage after key
15 Connection for stop button
16 J1587 / 1708 (bus)
17 Diagnostic outlet
18 Relay socket
19 Main relay
20 Main circuit breaker 10 A
21 Relay pre-heating
22 Pre-heating
23 Battery (24 V)
24 Starter motor
25 Alternator
27 Sensor, flywheel
28 Sensor, camshaft
30 Sensor, air inlet pressure / temperature
31 Connector block B
32 Connector block A
33 Control unit EMS 2
47701632 10-2012 © AB VOLVO PENTA 189

47701632 10-2012 © AB VOLVO PENTA
12 13 15 17
H L 14 16 A B 18
9 3 4 5 6 7 8
123 4 5 6
1 2 1 2
R/BL 1,5
SB 2,5
GR/Y
W/SB
R 2,5
Y/W
BL
W
10
8 19
1 2 86
Y/SB 1 85
INTERNAL
11 R/BL 1.5 2 87
SBY EGR R 1,5 4 30
12 345 6 7
R 1,5 3
SB Y SB
CAPILLERING
5
2 4 6 STOPPERS x2
4 SB SB B
(2) (1) (2) SB 2086
2P 1 R (1) 1 85
2 87
4 30
(4) 1 (2) 3 5 7 3
4 SB SB4
R/BL
(3) (1) R R1 2 5
2P 1 P2 1P
R/BL 1,5
R/BL 1,5
GN 1.0
BN/OR
GN/SB
SB 1.0
SB 1,5
SB 1,5
SB 1,5
BL/GN
BL/OR
BL/GR
GN/W
SB1,0
GN/R
GR/R
GR/R
GR/Y
BL/W
R 1.0
Y/W
LBN
R/Y
OR
Y
3 4 31 11 16 17 18 2827 2314 10 8 5256 30 29 25 5760 58 59 61 5155
31 h l h l
33
SB 2,5
32
R 2,5
B A
31 11 7 4722 15 29 4546 3738 3640 4448 5256 28 32 1216 2024 59 62 60 61 8 33 34 27 58 57
- + -
R/BL 1,5
GR/GN
GR/OR
SB 1,5
BN/OR
OR/SB
GR/SB
SB 1,0
GR/SB
W 1,5
W 1,5
W 1,5
W 1,5
W/SB
W 1,0
W 1,0
W 1,0
W 1,0
W 1,0
W 1,0
W 1,0
W 1,0
W 1,0
W 1,0
W 1,0
W 1,0
Y/SB
R 1,0
OR
SB
BL
W
29 VO/SB CAPILLERING
R3
STOPPERS x16
SB 1 2
P4 123 4
26 MAIN RELAY HOLD
123 4
30 CYL.1 24 21
4 1 26
R/BL 1,5
3 P2 12 12
n n CYL.2
26
SB 2,5
28 27
R 2,5
R/Y
25
TAD1250-1252VE
12345 PREHEAT
CYL.3
B+ KL 15 B- SB 25
26 G 31
M 30
R 25 22
P0014017
CYL.4
26
CYL.5 START 23
26
190
CYL.6
1 Sensor, oil level / oil temperature Cable colors

2 Sensor, oil pressure BL = Blue P = Pink
BN = Brown R = Red
3 Sensor, fuel pressure GN = Green SB = Black
4 Sensor, coolant temperature GR = Gray VO = Violet
5 Sensor, crankcase pressure LBL = Light blue Y = Yellow
6 Switch, coolant level LBN = Light brown
7 Switch, piston cooling pressure

8 Switch, water in fuel stated.
9 Connector block (not used)
10 Internal EGR
11 Extra stop
12 J1939 CAN (bus)
13 Battery negative
14 Battery plus
16 Stop button
17 J1587 / J1708 (bus)
18 Diagnostic tool
19 Main relay
20 Starter motor relay
22 Starter motor
23 Battery (24 V)
24 Pre-heating
25 Alternator
27 Sensor, flywheel
28 Sensor, camshaft
29 Sensor, air inlet pressure / temperature
31 Connector block B
32 Connector block A
33 Control unit EMS 2
47701632 10-2012 © AB VOLVO PENTA 191

7 10 28
CAN
29
BATT+ 1708
11 27
47701632 10-2012 © AB VOLVO PENTA

J1939 BATT- SWITCHED J1587
1 2 34 5 6 1 2
H L BATT+ STOP A B
W/SB
SB
W
1 2
R
1 2 1 2 3 4 5 6 7 8
CAN 2
R/BL 1,5
W/SB
SB 2,5
W
GR/Y
R 2,5
23 Y/W
BL
31 5
6 Y/SB 85
86
1
1 2 2 1 R/BL 1,5 R/BL 1,5
2
87
SB
30
Y
R 1,5
1 2 3 4 5 6 7 4
R
SB
Y
3
Y 1,0 5
24 8 21 R/BL
SB SB
4 2 2
SB
2P 1R 1 1
22 25 12 15
SB SB
4 1 4 41 4 R/BL 1,0
SB
R R 2
3 1 1 P2 1P
3 2 2 P 2
R/BL 1,5
R/BL 1,5
BN/OR
OR 1,0
BN 1,0
SB 1,0
BL/GR
GN/SB
BL/OR
BL/GN
SB 1,5
SB 1,5
SB 1,5
SB 1,0
GN/W
GN/R
GR/R
BL/W
GR/R
R 1,0
Y 1,0
GR/Y
Y/SB
Y/W
LBN
R/W
GN
Y
3 4 31 11 16 17 18 28 27 23 14 10 8 52 56 30 38 29 25 37 57 60 7 58 59 61 51 55
h l
CONNECTOR B
30
R 2,5
SB 2,5
CONNECTOR A b a
31 11 7 47 22 15 29 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24 59 62 60 61 8 33 34 27 58 57
GR/OR
SB 1,0
R 1,0
W/SB
BN/OR
VO/SB
Y/SB
SB 1,5
R/BL 1,5
OR/SB
GR/SB
GR/SB
Y 1,0
Y 1,0
Y 1,0
Y 1,0
GR/GN
Y 1,0
SB
Y 1,0
Y 1,0
Y 1,0
OR
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
BL
W
9
R
3
2
SB
1
P4 4231
4 3 MAIN RELAY HOLD
4231
26 2
CYL.1 1
17 19
OR 1,0
R/BL 1,0
BN 1,0
4 1
3 P2 2 1 2 1 4 3
n n
18
R/BL 1,5
2 1 R 25
CYL.2
Y/SB
R 2,5
R/W
13 14 20
SB 2,5
4 3 12345 SB 25
2 1
CYL.3 4 B+
G
B-
SB 25
M 30
3 31
4 3 R 25
2 1 2
CYL.4
TAD1350-1352GE
4 3
2
CYL.5
1
1
P0014018
4 3
2 1
CYL.6
192
16

2 Main switch BL = Blue P = Pink
BN = Brown R = Red
3 Starter motor GN = Green SB = Black
4 Alternator GR = Gray VO = Violet
5 Main relay LBL = Light blue Y = Yellow
6 Aux stop LBN = Light brown
7 Connector, engine interface

perature
10 VODIA input (diagnosis conn.)
11 Connector, development tool (not used)
13 Sensor, camshaft
14 Sensor, flywheel
15 Switch, piston cooling
17 Relay preheating
18 Fuse, preheating
20 Preheater
21 Switch, coolant level
23 Switch, water in fuel
27 Connector, remote stop
28 Jumper removable
29 EGR internal
30 Control unit EMS 2.2
31 Wastegate valve
47701632 10-2012 © AB VOLVO PENTA 193

47701632 10-2012 © AB VOLVO PENTA
1708
7
CAN BATT.+
HL BATT.+ STOP AB 28
11 10
1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 27
1 2
R/BL 1,5
W/SB
SB 2,5
CAN 2
SB
W/SB
GR/Y
R 2,5
W
R
Y/W
BL
W
23 29
5
1 2
6 Y/SB 85
86
1
2 1 R/BL 1,5 R/BL 1,5 87
SB Y 2
30
12 3 4 5 6 7 31 R 1,5
4
SB Y R
3
SB 1 2 5
24 8 21
Y 1,0
R/BL
4 SB SB 2 SB
2 SB 1,0
1 R 1 1
2P
22 25 12 15
4θ 1 4 SB SB 4
R/BL 1,0
SB
2
3 2 1 R R 1
1
2P P2 P
R/BL 1,5
R/BL 1,5
BN/OR
GN/SB
OR 1,0
BL/GN
BL/OR
BL/GR
BN 1,0
SB 1,0
SB 1,0
SB 1,5
SB 1,5
SB 1,5
GN/W
BL/W
GN/R
GR/R
GR/R
GR/Y
R 1,0
Y 1,0
Y/SB
30
LBN
R/W
Y/W
GN
Y
3 4 31 11 16 17 18 28 27 23 14 10 8 52 56 30 38 29 25 37 57 60 7 58 59 61 51 55
h l h h l
CONNECTOR B
SB 2,5
ba
R 2,5
CONNECTOR A
31 11 7 47 22 15 29 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24 59 62 60 61 8 33 34 27 58 57
- + -
GR/GN
SB
OR/SB
GR/SB
GR/SB
VO/SB
Y/SB
W/SB
R/BL 1,5
GR/OR
SB 1,0
BL
SB 1,5
R 1,0
BN/OR
OR
W
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
4 3 Y 1,0
9 CYL. 1
2 1
Y 1,0
R 3
SB SB 1 θ2 4 3 Y 1,0
4231
P4 CYL. 2 Y 1,0
4231
2 1 MAIN RELAY HOLD
26 4 3 Y 1,0
19
OR 1,0
R/BL 1,0
17
BN 1,0
CYL. 3 Y 1,0
4θ 1
2 1
P2
R/BL 1,5
2 1 2 1 4 3 Y 1,0 R 25
n n CYL. 4 Y 1,0 18
SB 2,5
13 14 2 1
20
R 2,5
Y/SB
R/W
TAD1353–55GE
4 3 Y 1,0 123 4 5
SB 25
CYL. 5 Y 1,0 B+ B-
2 1 4 G SB 25
31
M 30
4 3 Y 1,0
R 25 3
CYL. 6 Y 1,0
P0012806
2 1 1 2
16
194
START
- +

BN = Brown R = Red

perature
13 Sensor, camshaft
14 Sensor, flywheel
17 Relay preheating
18 Fuse, preheating
20 Preheater
28 Jumper removable
29 EGR internal
31 Wastegate valve
47701632 10-2012 © AB VOLVO PENTA 195

47701632 10-2012 © AB VOLVO PENTA
7
CAN BATT.+ 1708
HL BATT.+ STOP AB 28
11 10
1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 27
1 2
R/BL 1,5
W/SB
SB 2,5
CAN 2
SB
W/SB
GR/Y
R 2,5
W
R
Y/W
BL
W
23 29
5
1 2
6 Y/SB 85
86
1
2 1 R/BL 1,5 R/BL 1,5 87
SB Y 2
30
12 3 4 5 6 7 31 R 1,5
4
SB Y R
3
SB 1 2 5
24
R/BL 1,5
8 21
Y 1,0
R/BL
4 SB SB 2 SB
2 SB 1,0
1 R 1 1
2P
22 25 12 15
4θ 1 4 SB SB 4
R/BL 1,0
SB
2
3 2 1 R R 1
1
2P P2 P
R/BL 1,5
R/BL 1,5
BN/OR
GN/SB
OR 1,0
BN 1,0
BL/GN
BL/OR
BL/GR
BN 1,0
SB 1,0
SB 1,0
SB 1,5
SB 1,5
SB 1,5
GN/W
BL/W
GN/R
GR/R
GR/R
GR/Y
R 1,0
Y 1,0
Y/SB
30 LBN
R/W
Y/W
GN
Y
49 3 4 31 11 16 17 18 28 27 23 14 10 8 52 56 30 38 29 25 37 57 60 7 58 59 61 51 55
h l h h l
CONNECTOR B
R/BL 1,0
SB 2,5
ba
R 2,5
CONNECTOR A
31 11 7 47 22 15 29 35 39 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24 59 62 60 61 8 33 34 27 58 57
TAD1341-45GE, TAD1340-45VE Visco fan
- + -
GR/GN
GN
SB
OR/SB
GR/SB
GR/SB
VO/SB
Y/SB
W/SB
R/BL 1,5
GR/OR
SB 1,0
BL
BL
SB 1,5
R 1,0
BN/OR
OR
W
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
4 3 Y 1,0
9 CYL. 1
2 1
Y 1,0
R 3
SB SB 1 θ2 4 3 Y 1,0
4231
P4 CYL. 2 Y 1,0
4231
2 1 MAIN RELAY HOLD
R
26 4 3 Y 1,0
19
OR 1,0
R/BL 1,0
17
BN 1,0
CYL. 3 Y 1,0
4θ 1
2 1
3 P2
R/BL 1,5
2 1 2 1 4 3 Y 1,0 R 25
n n CYL. 4 Y 1,0 18
SB 2,5
13 14 2 1
20
R 2,5
Y/SB
R/W
4 3 Y 1,0 12 3 4 5
SB 25
CYL. 5 Y 1,0 B+ B- SB 25
BC AE D F 2 1 4 G
31
M 30
4 3 Y 1,0
R 25 3
CYL. 6 Y 1,0
P0012805
n 2 1 1 2
16
196
START
32 - +
1 Battery Visco electric fan

2 Main switch A = Fan speed sensor supply
B = Clutch contol high
3 Starter motor C = Clutch control low
4 Alternator D = Fan speed sensor ground
E = Fan speed output
5 Main relay F = Not connected
6 Aux stop
Cable colors
BL = Blue P = Pink
8 Sensor, coolant temperature BN = Brown R = Red
GN = Green SB = Black
GR = Gray VO = Violet
perature
10 VODIA input (diagnosis conn.) LBL = Light blue Y = Yellow
LBN = Light brown
13 Sensor, camshaft stated.
14 Sensor, flywheel
17 Relay preheating
18 Fuse, preheating
20 Preheater
28 Jumper removable
29 EGR internal
31 Wastegate valve
32 Visco elecric fan
47701632 10-2012 © AB VOLVO PENTA 197

47701632 10-2012 © AB VOLVO PENTA
7 15 10 12 11
A BH L 14 13
5 16 8
SB
Y
7 8 1 2 6 4 5 3
(1) (2) SB 1234567 1 2
17 1 2
2 6
R/BL1,5
34
SB
GR/SB
Y
SB2,5
CAN2
R2,5
R 1
1
c°
2 1
P
2 32
SB 4
P2
4 R/BL
1
33
7 SB
SB
2 1
R/BL1,5
R/BL
9
3 R/BL1,0
SB
SB
1 4
R
(4) R/BL1,5
(3)
(2) (1)
R 1
19
(1) B SB SB 4 P
L (2) 2 86
Y/SB 85
R2,5
1
R/BL1,5 87
SB2,5
2
30
R/BL1,5
R/BL1,5
R1,5
BL/GN
GN/SB
BN/OR
SB1,0
BL/OR
BL/GR
GR/R
BN1,0
4
BN/Y
GN/W
R/Y1,0
SB1,0
SB1,5
SB1,5
SB1,5
BL/W
GN/R
GR/Y
LBL
R1,0
Y/W
R1,5
GR
OR1,0
GN
VO
3
Y
11 3 4 16 27 17 18 28 31 14 23 44 10 8 34 38 57 60 7 51 55 52 56 58 59 61 29 25 5
36 CONNECTOR B h l h l
37
35 CONNECTOR A + - - + BA
SB1,5
7 11 15 29 47 22 31 45 46 37 38 20 24 12 16 28 32 52 56 44 48 36 40 60 61 59 62 27 33 34 58 8 57
+ - -
GR/SB
GR/GN
SB1,0
OR/SB
GR/SB
GR/SB
VO/SB
W1,0
W1,0
W1,0
W1,0
W1,0
W1,0
W1,0
W1,0
W1,0
W1,0
W1,0
W1,0
W1,5
W1,5
BN/OR
GR/OR
R/BL1,5
W1,5
W1,5
30
R1,0
OR
W/SB
SB
Mainrelay
Hold
W
1 P
2 Y/SB
3 CAPILLERING
4 STOPPERSx16
R2,5
29
SB 1
2
R
3
P4
4
2
3
1 20
0-6BAR CYL.6 4231
31 2 1 2 1
R/BL1,0
OR1,0
n n
25
BN1,0
SB 4 4 3
3 2 1
R 1
P2 28 27 CYL.5
4 3
W/SB
2 1
SB
W
CYL.4
R
6 5 4 3 2 1
R/BL1,5
R/Y1,0
SB2,5
4 3
R2,5
2 1
CYL.3
18 R/BL1,5
KL15 50
1 2345
3 31 30
4 B+ B-
2 1 M
G
CYL.2
23 SB25 21
4 3 R25
2 1 R25
SB25
CYL.1
SB70
R70
26
TWD1643GE
SCHPOS
P0014019
198
22
1 Sensor, oil level / oil temperature Cable colors

2 Sensor, fuel pressure BL = Blue P = Pink
BN = Brown R = Red
3 Sensor, crankcase pressure GN = Green SB = Black
4 Sensor, coolant temperature GR = Gray VO = Violet
5 Switch, coolant level LBL = Light blue Y = Yellow
6 Switch, piston cooling pressure LBN = Light brown

8 Connector (not used) stated.
9 Extra stop
10 J1939 CAN (bus)
11 Battery negative
12 Battery plus
14 Stop button (press button)
15 J1587 (bus)
16 Jumper
17 Aux stop
19 Main relay
21 Starter motor
22 Battery (24 V)
23 Alternator
24 Pre-heating
25 Relay pre-heating
27 Sensor, flywheel
28 Sensor, camshaft
perature
32 Thermostat by-pass valve
33 Wastegate valve
34 Sensor, exhaust temperature
35 Connector A
36 Connector B
37 Control module EMS 2
47701632 10-2012 © AB VOLVO PENTA 199

47701632 10-2012 © AB VOLVO PENTA
CAN BATT.+ 1708
7
HL BATT.+ STOP AB
11 10
1 2 3 4 5 6 7 8 1 2 3 4 5 6
1 2
R/BL 1,5
W/SB
GR/SB
SB 2,5
CAN 2
SB
W/SB
GR/Y
R 2,5
W
R
Y/W
W
23 26
5
1 2
6 Y/SB 85
86
1
2 1 R/BL 1,5 87
SB Y 2
30
12 3 4 5 6 7 28 R 1,5
4
SB Y R
3
1 2 5
21
R/BL 1,5
8
Y 1,0
R/BL
SB SB 2 SB
2 SB 1,0
1 1
22 25 12 15
4θ 2 4 SB SB 4
R/BL 1,0
SB
2
3 1 1 R R 1
1
2P P2 P
R/BL 1,5
R/BL 1,5
BN/OR
GN/SB
OR 1,0
BL/OR
BL/GR
BN 1,0
SB 1,0
SB 1,0
SB 1,5
SB 1,5
SB 1,5
GN/W
BL/W
GN/R
GR/R
GR/R
GR/Y
R 1,0
Y 1,0
Y/SB
27 LBN
R/W
Y/W
GN
Y
3 4 11 16 17 18 28 27 23 14 10 8 52 56 30 38 29 25 37 57 60 7 58 59 61 51 55
h l h h l
CONNECTOR B
SB 2,5
ba
R 2,5
CONNECTOR A
31 11 7 47 22 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24 59 62 60 61 8 33 34 27 58 57
- +
GR/GN
OR/SB
GR/SB
GR/SB
VO/SB
Y/SB
W/SB
GR/SB
R/BL 1,5
GR/OR
SB 1,0
SB 1,5
R 1,0
BN/OR
W
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
4 3 Y 1,0
9 CYL. 1
2 1
Y 1,0
R 3
SB 1 θ2 4 3 Y 1,0
4231
P4 CYL. 2 Y 1,0
4231
2 1 MAIN RELAY HOLD
24 4 3 Y 1,0
19
OR 1,0
R/BL 1,0
17
BN 1,0
CYL. 3 Y 1,0
4
2 1
P2
R/BL 1,5
2 1 2 1 4 3 Y 1,0 R 25
BL/OR
n n CYL. 4 Y 1,0 18
SB 2,5
13 14 2 1
20
R 2,5
Y/SB
R/W
4 3 Y 1,0 123 4 5
SB 25
CYL. 5 Y 1,0
TAD1650VE
B+ B-
2 1 4 G SB 25
31
M 30
4 3 Y 1,0
R 25 3
CYL. 6 Y 1,0
P0012803
2 1 1 2
16
200
START
- +

BN = Brown R = Red

perature
13 Sensor, camshaft
14 Sensor, flywheel
17 Relay preheating
18 Fuse, preheating
20 Preheater
26 EGR internal
28 Wastegate valve
47701632 10-2012 © AB VOLVO PENTA 201

47701632 10-2012 © AB VOLVO PENTA
CAN BATT.+
7 1708
J1939 BATT.- BATT.+ SWITCHED J1587
11 H L STOP AB 28 10
1 2
1 2 3 4 5 6 7 8 1 2 27 1 2 3 4 5 6
CAN 2
23
W/SB
SB
R
W
R/BL 1,5
W/SB
SB 2,5
R 2,5
BL
Y/W
W
SB Y GR/Y
25 12 3 4 5 6 7
4
R 1 SB Y
86
Y/SB 85
SB 4 1
P2 R/BL 1,5 R/BL 1,5 87
2
R 1,5 30
4
12 21 5 R 1,5
3
R 1 B
(1) (2) 5
SB 4 R/BL
P2 C
22 8 15
CAN j1939
SB
SB
B
CAN 2
R 2,5
(3) (4) (2) P2 SB
(1) 1
(1) (2)
R/BL 1,5
R/BL 1,5
BN/OR
GN/SB
BL/OR
BL/GN
BL/GR
SB 1,0
SB 1,0
SB 1,5
SB 1,5
SB 1,5
GN/W
GR/W
BL/W
GN/R
GR/R
GR/Y
R 1,0
6
LBN
Y/W
R/Y
OR
Y
11 31 3 4 17 18 27 28 16 23 14 10 8 52 56 57 60 51 55 58 59 61 29 25
h l h l
CONNECTOR B
CONNECTOR A BA
7 11 47 22 15 29 31 45 46 37 38 40 48 56 32 16 24 59 60 8 33 34 27 58 57
+ - -
GR/GN
GR/OR
SB
OR/SB
GR/SB
GR/SB
VO/SB
Y/SB
W/SB
R/BL 1,5
SB 1,0
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
BL
SB 1,5
R 1,0
BN/OR
OR
W
24 9
4 SB SB
1
3 1 2 34
θ 1
R R 3 θ2
2P P4
CAPILLERING 17 19
26 STOPPER x8
TAD1640-42GE, TAD1641-43VE
4θ MAIN RELAY HOLD

1 R 25
3 CYL. 1
18
P2
20
2 1 2 1 CYL. 2 SB 25
n n
13 14 CYL. 3
SB 2,5
SB 25
R/BL
R 2,5
R/BL
R 25
R/Y
CYL. 4 KL 15 50
123 4 5
B+ B- SB 25 31 M 30 2
CYL. 5
3 G
R 25
P0012804
CYL. 6
1
202
START
16 - +

2 Starter motor BL = Blue P = Pink
BN = Brown R = Red
3 Alternator GN = Green SB = Black
4 Main relay GR = Gray VO = Violet
5 Stop switch LBL = Light blue Y = Yellow
6 Control unit EMS 2 LBN = Light brown
7 Connector - engine interface

perature
10 Connector diagnostic J1587
11 Connector - application tool
13 Sensor, camshaft
14 Sensor, flywheel
15 Switch, piston cooling pressure
17 Pre-heater relay
18 Fuse
19 Fuse 10A
20 Pre-heater
22 Sensor, oil level
27 Aux stop
28 Jumper - removable
47701632 10-2012 © AB VOLVO PENTA 203

7 BATT.-
CAN BATT.+
1,0 BL/R J1708 J1708
B A
HL AB
47701632 10-2012 © AB VOLVO PENTA

BATT.+ STOP
BATT.+ 10
11 1 2 3 4 5 6
1 2 3 4 5 6 7 8 5
0,75 W
0,75 W/SB
0,75 SB
0,75 R
1 2 2 3
0,75 W/SB
1,5 R/BL
0,75 BL
CAN 2
0,75 W
2,5 SB
0,75 GR/Y
0,75 Y/W
2,5 R
4 5 1
2 23 30 1,5 R
0,75 R
6 1,0 R
1 2 1 1,5 BL/R
0,75 SB Y
12 3 4 5 6 7
0,75 SB Y 28
0,75 SB
1 2
1,5 R/BL
0,75 R/BL
24 8
0,75 SB 0,75 SB
4 2 1,0 SB
0,75 R
1 1
2P
0,75 SB
22 25 12 15
4θ 1 4 0,75 SB 0,75 SB 4 2 1,0 R/BL
3 2 1 0,75 R 0,75 R 1
1
2P P2 P
0,75 BL/GR
0,75 BL/OR
0,75 BN/OR
0,75 BL/GN
0,75 GN/SB
0,75 BL/W
0,75 GN/R
0,75 GN/W
0,75 Y/SB
0,75 GR/R
0,75 R/W
0,75 GR/Y
0,75 GN
1,5 R/BL
1,5 R/BL
1,0 OR
0,75 Y/W
0,75 SB
0,75 W
1,0 BN
1,0 BN
0,75 Y
1,0 SB
1,5 SB
1,5 SB
1,5 SB
1,0 R
1,0 Y
49 3 4 31 11 16 17 18 28 27 30 23 10 8 52 56 38 29 25 37 57 60 7 58 59 61 51 55
h l h l
CONNECTOR B
27
2,5 SB
2,5 R
CONNECTOR A
31 11 7 47 22 15 29 35 39 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24 59 62 60 61 8 33 34 27 58 57
- + -
0,75 OR/SB
0,75 GR/GN
0,75 SB
0,75 OR/SB
0,75 GR/SB
0,75 Y/SB
0,75 W/SB
1,5 R/BL
0,75 GR/OR
0,75 BL
0,75 BL
1,5 SB
0,75 BN/OR
0,75 OR
0,75 W
1,0 SB
1,0 R
0,75 GN
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
1,0 Y
0,5 GR/W
1,0Y
4 3 Y 1,0
Y 1,0
CYL. 1 2 1
9
0,75 R
4 3 Y 1,0
3 1 2
P 4231
4 Y 1,0
0,75 SB 0,75 SB 4231
CYL. 2 2 1 MAIN RELAY HOLD
1 4
0,75 R
26 4 3 Y 1,0
OR 1,0
19
R/BL 1,0
17
BN 1,0
4 1 1 Y 1,0
TAD1650-51GE Visco fan
P4 CYL. 3 2 1
R/BL 1,5
2 1 2 1 4 3 Y 1,0 R 25
2
3
n n 18
Y 1,0
SB 2,5
2 1
13 14
R 2,5
20
Y/SB
CYL. 4
R/W
4 3 Y 1,0 123 4 5
SB 25
Y 1,0 B+ B- SB 25
BC AE D F CYL. 5
2 1 4 G
31
M 30
4 3 Y 1,0
R 25 3
Y 1,0
2
P0014271
n 2
CYL. 6
1
1
16
204
START
29 - +
1 Battery Visco electric fan

2 Main switch A = Fan speed sensor supply
B = Clutch contol high
3 Starter motor C = Clutch control low
4 Alternator D = Fan speed sensor ground
E = Fan speed output
5 Main relay F = Not connected
6 Aux stop
Cable colors
7 Connector, engine interface (8-pin)
BL = Blue P = Pink
8 Sensor, coolant temperature BN = Brown R = Red
GN = Green SB = Black
GR = Gray VO = Violet
perature
10 VODIA input (diagnosis conn., 6-pin) LBL = Light blue Y = Yellow
LBN = Light brown
13 Sensor, camshaft stated.
14 Sensor, flywheel
17 Relay, preheating
18 Fuse, preheating
19 Main circuit breaker, 10 A
20 Preheater
21 Preheat connector (4-pin)
23 EGR internal
28 Wastegate valve
29 Visco elecric fan
30 WIF connector
47701632 10-2012 © AB VOLVO PENTA 205

Wiring diagram CIU

1 2 3 4 5 6 7 8 23
30
R/BL 1,5
GR/Y
R 2,5
W/SB
Y/W
SB 2,5 SB 1,5
W
14
SB 2,5
27
R 2,5 1
R 1,5
R/BL 1,5 R/BL 1,5
28
W
22
W/SB
37
R/BL 1,5
Y/W
SB 2,5
GR/Y
R 2,5
Y/W
12
W/SB
W
11 GR/Y
GN/Y
30 1 2 3 4 5 6 7 8 27
2
SB
GN/SB
2
1 2 3 4 5 6 7 8
3
GN/OR 26
24
29 R/W R
R/GR 8 SB SB
1
R/BN 9 R/SB
15
10
R/BL
R/Y
R/BL
R/BL
35
R/BL
SB
VO 11
41 7
SB
12
SB
P
SB
SB
16
25 3
R SB - 7
10 BN RPM/M + SB
R/SB R/SB
13
SB
4
33 GR/SB - P + 7
G SB
R/SB
LBN
SB
21
5
26 W/BL 13 R - C
+ 7
R/SB G
Y
20 6
BL/Y 14 R - C +
40
R/SB G
LBN
34
W/BN 15 R
9
W/GN 16
25
39 BL/OR 17
36 P/SB 18
7 VO/W 19
38 GL 20
R/GN 21
24
OR 22
17
R/SB 29
19
W/GL 28 1
SB
2
Y/BL R
8 3
P0014020
206 47701632 10-2012 © AB VOLVO PENTA

1 Key switch (15+) Cable colors

2 RPM potentiometer BL = Blue P = Pink
BN = Brown R = Red
3 Tachometer (code 14) GN = Green SB = Black
4 Oil pressure, instrument GR = Gray VO = Violet
5 Oil temperature, instrument LBL = Light blue Y = Yellow
6 Coolant temperature, instrument LBN = Light brown
7 Instrument illumination
8 Idling contact, two-way stated.
9 1500 / 1800 rpm switch, two-way
10 Starter contact, spring biased
11 Stop switch, spring biased
12 Diagnosis contact, spring return
13 Alarm, low oil pressure
14 Alarm, high oil temperature
15 Alarm, high coolant temperature
16 Alarm, low coolant level
17 Fuel alarm
18 Diagnostic lamp
19 Engine overspeed indication (GE) Horn (VE)
20 Operation indicator
21 Pre-heating indication
22 Pre-heating contact
23 8-pin connector engine interface
24 Governor switch
25 Battery voltage alarm
26 Termination resistance 120 Ohm
28 Contact, engine protector disconnect
29 Easy Link connector block
30 Control Interface Unit (CIU)
47701632 10-2012 © AB VOLVO PENTA 207


TAD1640VE-B, TAD1641VE-B, TAD1642VE-B
0,75 SB
0,75 SB
0,75 SB
0,75 GR/OR
B C A E D F
B C A E D F
29 1 BN
1
CONNECTOR A
CONNECTOR B
28
49
31 11
0,75 SB 1 SB 0,75 GN/SB
P1/4
3
0,75 R 1R 0,75 GN/W
BC AED F
4
0,75 R
0,75 BL/GN
0,75 BN/OR
n
31
47
0,75 R 27 0,75 GN/GR 0,75 BL/OR
22
11
0,75 SB 0,75 GN/R
2 5
P1/4
15 29
16
0,75 OR
0,75 GN
P
P
35 39
0,75 BL
0,75 SB
0,75 R
0,75 OR/SB
26
45 46
n
0,75 GR/SB
1R 0,75 R
1 BL/R
17
0,5 GR/W
25
37 38
n
0,75 OR/SB 1 SB 0,75 SB
18
1Y
Y 0,75 SB
36
0,75 R
1Y
0,75 SB
40
44 48
30 3 4
1/4
P
0,75 GR/R
52 56
1 SB
28
0,75 BN/OR
28 32
27
24 1R
12 16
0,75 BL
5
0,75 VO
20 24
CYL.6
CYL.5
CYL.4
CYL.3
CYL.2
CYL.1
1
1Y
M
1
2 3 4
0,75 GR
6
24
IC
5
NCV
NCV
NCV
NCV
NCV
NCV
2
2
4
0,75 W
7
3 1
3 1
3 1
3 1
3 1
3 1
SV
SV
SV
SV
SV
SV
23
0,75 SB
1Y
1Y
0,75 SB
10
1Y 0,75 Y
1 2 3 4 5 6 7
1Y
8
1Y
1Y
1Y
0,75 SB
59
1Y 1Y
1Y
62
1Y 0,75 P
8
1Y 1Y
22 21
H L
0,75 BN/P
60
11
1Y 1Y
1Y
61
0,75 BL/W
0,75 Y/SB J1939 H
1 2 3 4 5 6
52 56
H L
0,75 BL/GR
8
J1939 L
1,5 BL/R
0,75 GN BAT+MAIN REL.
0,75 W/SB
38
33
MAIN RELAY HOLD
0,75 W
0,75 Y/SB J1708 A
0,75 W/SB
29
0,75 BL/R
0,75 W J1708 B
34
1 OR
10
25
0,75 BL
0,75 R/W
27
37
1,5 BL/R 1,5 BL/R

9
58
57
1,5 BL/R 1,5 BL/R

1,5 SB
60
57
23 1 BN
7
0,75 BL/W
%RH
23 43
0,75 BN 1,5 SB
NTC
1,5 BL/R
58
1,5 SB
59
1,5 SB
61
0,75 Y/W
51
0,75 Y/GR 12
55
J1939 H
1 2 3 4 5 6 7 8
22 2,5 SB
2,5 R
J1939 L
BAT.-
BAT.+
BAT. SWITC.
G
1 BL/R
STOP
0,75 W
J1708 A
0,75 W/SB
J1708 B
0,75 R
25 SB
2,5 SB
13
25 R
0,75 R
BAT.+
1 2 3 4 5 6
0,75 W/SB
J1708 B
4 SB 0,75 SB
BAT.-
CAN3 HIGH
0,75 W
J1708 A
21
SB
15 CAN3 LOW
M
SW
R
87
30
87a
20
25 SB
R
86
85
19 17
1,5 R
0,75 R
4R 2,5 R 2,5 R
18 4 SB
4R 4R 14
16
25 R
1 BN
4 3 2 1
4 3 2 1
1 OR
1 BL/R 1 BL/R
1 SB
208 47701632 10-2012 © AB VOLVO PENTA

1 Sensor, oil level / temperature 17 Fuse, 10 A

2 Sensor, fuel pressure 18 Fuse, 30 A
3 Sensor, crankhouse pressure 19 Starter motor
4 Sensor, coolant temperature 20 Main switch
5 Sensor, oil pressure 21 Battery
6 Throttle 22 Alternator
7 Switch, coolant level 23 Humidity sensor
8 Water in fuel connector 24 Unit injector (cyl. 1-6)
9 Stop button 25 Sensor, crank
10 VGT control valve 26 Sensor, camshaft
11 6-pole EATS connector 27 Air filter indicator
12 8-pole engine connector 28 Electric fan
13 6-pole diagnosis connector 29 Sensor, air inlet pressure / intake mani-
14 2-pole EATS connector fold temperature
15 Main relay 30 Control unit EMS2
16 4-pole pre-heat connector
Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Grey
OR = Orange
P = Pink
R = Red
SB = Black
VO = Purple
W = White
Y = Yellow
Cable cross section = 0,75 mm² unless otherwise stated.
47701632 10-2012 © AB VOLVO PENTA 209


P0014339
210 47701632 10-2012 © AB VOLVO PENTA

1 Sensor, oil level/temp Cable colors

BL = Blue
LBL = Light blue
3 Sensor, crankhouse pressure BN = Brown
LBN = Light brown
GN = Green
5 Sensor, coolant temperature GR = Gray
OR = Orange
6 Throttel
P = Pink
7 Coolant level switch R = Red
SB = Black
8 WIF connector
Vo = Violet
9 VGT control valve W = White
Y = Yellow
10 Stop button
11 6-pole EATS connector Wire cross-sectional area = 0.75 mm² unless oth-
erwise stated.
12 8-pole engine connector
13 6-pole diagnosis connector
14 2-pole EATS connector
15 Main relay
16 4-pole pre-heat connector
17 Fuse 10 A
18 Fuse 30 A
19 Starter motor
20 Main switch
21 Battery 24V
22 Alternator
23 Plug connection / alternator
24 Humidity sensor
25 Unit injectors cyl.1-6
26 Crank sensor
27 Camshaft sensor
28 Airfilter indicator
29 Electric fan
30 Boost air temp/press
31 Control unit EMS (conn, A/B)
47701632 10-2012 © AB VOLVO PENTA 211

Wiring Diagram TWD1663GE / TWG1663GE

NOTICE! Wiring diagram used for both engine types, TWD and TWG together.
7
0.75 SB
0.75 SB POWER
1 2 3 4 5 6 7 8 9 10 11 12
B C A E D F
B C A E D F
THROTTLE POSITION
30
0.75 GN/OR
22
PWM -
32 EA31 EB49 1 BN
0.75SB 1SB
EA11 EB3 0.75 GN/SB
P
0.75R GROUND
B
1R 0.75 GN/W
3 4
EA7 EB4
C
0.75R
1
A
0.75 BL/GN
E 0.75 BN/OR EB31
1 BL/R
EA47
D
0.75 GN/GR
EA22 EB11 0.75 BL/OR
31 P
EB9 0.75 BL
2
23
0.75SB
20 P
EA15
0.75OR 0.75 GN
EA29 EB13
2
0.75GN 0.75 GN/R
EA35 EB16 PWM +
P
0.75BL
4
EA39
1
4
0,75 SB
0.75 OR/SB
1
0,75R
24
EA45
33 34
0.75 GN/SB
EA46 1R 0,75R
EB17
0.75 GR/W
EA37
0.75 OR/SB 0.75 SB
EA38 EB18 1SB
1Y 0.75 SB
EA36
0,75R
1Y
0.75 SB
EA40
1Y
25 P
21
EA44
1Y
EA48
1 2 3 4
1
1Y EA52 0.75 GR/R 0.75 W/SB
1Y EA56 EB28
1
4
2
2
1Y
EA28 EB27 0.75 BN/OR
1Y EA32 0.75 GR
9
1Y EB24
EA12
1 2 3 4
1Y
EA16 EB54 0.75 VO 0.75 W/SB
1Y EA20 EB35 0.75 W/SB
2
1Y EA24 EB36 0.75 P/SB
0.75 P/W
EB40
0.75 VO
EB34
2 4 3 1
2 4 3 1
2 4 3 1
2 4 3 1
2 4 3 1
2 4 3 1
28
35
1
26
0.75 W
EB23
4
1
2
30
1Y
1Y
0.75 SB
EB10 0.75 SB
1Y 0.75 Y
0.75 BL/R
1 2 3 4 5 6
1Y 1Y EA59 EB8 0.75 SB
1Y
1Y
1Y 1Y
1Y EA62
27
0.75 BL/R
1Y 0.75 P
1Y 1Y EB22
EA60 0.75 BN/P
1Y EB21
1Y
1Y
7
EA61
10 1
0.75 BL/W
0.75 Y/SB EB52 J1939 H
EA8 0.75 BL/GR
EB56 J1939 L
2 3 4
1.5 BL/R BAT + (MAIN RELAY)
0.75 W/SB EB38 0.75 GN
EA33
0.75 W
0.75 Y/SB J1708 A
5 6
EB29 0.75 W/SB
2
0.75 W J1708 B
297
0.75 BL/R
EA34
1 OR
EB25
1
0.75 BL EA27 0,75 R/W 0.75 BL/R
11
EB37
1.5 BL/R EA58 EB57 1.5 BL/R BAT. SWITCED
1
ON/OFF
2
0.75 SB
1.5 BL/R
1.5 SB EA57 EB60
6
1 BN
EB7
1.5 BL/R
1.5 SB
1.5BL/R
EB58
12
1.5 SB
EB59
1.5 SB LOAD INPUT

1
1
EB61
GAS REQUEST
2
2
EB51 0.75 Y/W
13 1
0.75 Y/GR
EB55
0.75 GR/W J1939 H
EB46
0.75 BN/SB J1939 L
2 3 4
EB47 2.5 SB
4
0.75 BN/W BAT -

EB48 2.5 R
BAT +
1 2 34 5
1 BL/R
- G+
BAT. SWITCED
5 6 7 8
STOP
0.75 W
J1708 A
0.75 W/SB
J1708 B
25 SB
2.5 SB
14
25 R
0.75 R
BAT +
1 2 3 4
0.75 W/SB
J1708 B
4 SB 0.75 SB
BAT -
CAN 3 HIGH
0.75 W
J1708 A
5 6
SB CAN 3 LOW
- M+
SW
1
4 5 1
R
87
30 86
2
87a 85
5 0.75 R
25 SB
R
3
2
1.5 R
15
4R 2.5 R 2.5 R
2
1
16
4 SB
2 1
4R 4R
1
2
17
2
19
1 BN
4 3 2 1
4 3 2 1
25 R
1 OR
1
18
1 BL/R 1 BL/R
3
1 SB
1
P0015343
212 47701632 10-2012 © AB VOLVO PENTA

Description for wiring diagram

TWD1663GE / TWG1663GE

BL = Blue
2 Main switch
LBL = Light blue
3 Starter motor BN = Brown
LBN = Light brown
4 Alternator
GN = Green
5 Main relay GR = Gray
OR = Orange
6 Aux stop
P = Pink
7 12-pole connector, Gas throttle (gas valve) R = Red
SB = Black
8 4-pole connector, Knock sensor 1
VO = Purple
9 4-pole connector, Knock sensor 2 W = White
Y = Yellow
10 6-pole connector, EATS
11 2-pole connector, Gas supply valve stated.
12 2-pole connector, Gas flow, Alternator load
Visco electric fan
13 8-pole connector, Engine interface C = Clutch control low
14 6-pole connector, VODIA diagnos B = Clutch control high
A = Fan speed sensor supply
15 2-pole connector, power supply EATS E = Fan speed output
16 Fuse, main circuit engine, 10A D = Fan speed sensor ground
F = Not connected
17 Fuse, power supply EATS 30 A
18 Fuse, pre-heating
19 4-pole connector, pre-heating
20 Sensor, Oil pressure
21 Sensor, Coolant temperature
22 Sensor, oil level temp
23 Lisk valve (wastegate)
24 Sensor, Fuel Pressure
25 Sensor, Crankhouse pressure
26 Cold start valve
27 6-pole connector, WIF
28 Switch, Coolant Level
29 Wastegate Valve
30 Unit injector (Cyl 1-6)
32 Visco electric fan
33 Sensor, Camshaft
34 Sensor, Flywheel (crank)
47701632 10-2012 © AB VOLVO PENTA 213

Wiring diagram DCU

1 2 3 4 5 6 7 8 8
SB 2,5
BL 2,5
11
W/SB
GR/Y
R 2,5
Y/W
W
R/BL 1,5
1
Y/W
2
GR/W
SB 2,5
3
R 2,5
4
R/BL 2,5
5
6
BL 2,5
7
W
8 W/SB
R/BL 1,5
SB 2,5
BL 2,5
W/SB
3
GR/Y
R 2,5
Y/W
W
1 1
1
VO 1 2 3 4 5 6 7 8 9
D 2 4
R/Y
C 2 1 2 3 4 5 6 7 8 10
U SB/Y
3
R/BL
4 5
1
Y
5 2
3
SB
6
GN/R
7
GN/Y
8 6
GN/SB
9
7
SB/VO
10
11
SB/GR
12
SB/W
P0014021
1 Stop contact Cable colors

2 Start contact BL = Blue P = Pink
BN = Brown R = Red
3 1-pin connector GN = Green SB = Black
4 Horn, buzzer alarm GR = Gray VO = Violet
5 Easy Link connector LBL = Light blue Y = Yellow
6 RPM-potentiometer LBN = Light brown
7 Indicator engine operation

8 8-pin connector engine interface stated.
10 Termination resistance 120 Ohm
11 Display Control unit (DCU)
214 47701632 10-2012 © AB VOLVO PENTA

39-0 General
39-0 General
Index
MID 128
Caption SPN Flashcode FMI
Electrical fault /
value fault
MID 128, PID 45 Inlet air heater status page 64 626 5.4/- 3, 4, 5
MID 128, PID 94 Fuel Delivery Pressure page 66 94 3.6/3.8 1, 3, 5, 7
MID 128, PID 97 Water in fuel indicator page 69 97 2.9/2.1 0, 3
MID 128, PID 98 Engine oil level page 71 98 5.9/5.7 1, 5
MID 128, PID 100 Engine oil pressure page 73 100 3.1/6.6 1, 3, 5
MID 128, PID 105 Intake manifold temperature page 76 105 3.2/6.2 0, 4, 5
MID 128, PID 106 Air inlet pressure page 78 106 3.4/3.5 0, 3, 5
MID 128, PID 107 Air filter pressure drop page 81 107 5.5/5.5 1, 3, 5
MID 128, PID 108 Barometric pressure page 84 108 -/- 2, 3, 4
MID 128, PID 110 Engine coolant temperature page 85 110 3.3/6.1 0, 4, 5
MID 128, PID 111 Coolant level page 88 111 2.3/2.2 1, 3
MID 128, PID 153 Crankcase pressure page 90 153 7.8/7.7 0, 3, 5
MID 128, PID 158 ECU battery potential page 93 158 -/3.9 (EMS) 1
-/6.9 (CIU)
MID 128, PID 172 Inlet air temperature page 94 172 7.9/- 4, 5
MID 128, PID 173 Exhaust gas temperature page 96 1184 -/- 0, 4, 5
MID 128, PID 175 Engine oil temperature page 98 175 3.7/5.8 0, 4, 5
MID 128, PID 190 Engine speed page 100 190 -/2.6 0
MID 128, PPID 3 Starter Output page 101 677 4.6/- 3, 4, 5
MID 128 / 144, PPID 4 Starter input sensor page 103 - 4.7/5.2 3, 4
MID 128, PPID 6 Key off input sensor page 104 520195 4.8/- (EMS) 4
970 5.3/- (CIU)
MID 128, PPID 8 Piston Cooling Oil Pressure page 105 520192 6.8/6.7 1, 3
MID 128, PPID 19 Internal EGR Status page 107 2791 5.5/- 3, 4, 5, 7
MID 128, PPID 55 ECU temperature page 110 - - 0, 4, 5
MID 128, PPID 98 Engine sync acknowledge page 111 608 -/- 9
MID 128 / 144, PPID 132 Throttle calibrated position page 112 608 2.8/- 3, 4, 9
MID 128, PPID 332 Thermostat page 114 2988 -/- 3, 4, 5
MID 128, SID 1/2/3/4/5/6 Injector # 1-6 page 116 651–656 7.1/7.6/- 3, 4, 5, 7, 12
MID 128, SID 21 Engine position page 120 636 2.5/- 2, 3, 8
MID 128, SID 22 Timing sensor, crank page 122 637 2.4/- 2, 3, 8
MID 128, SID 32, Wastegate output driver page 124 1188 -/- 3, 4, 5
MID 128, SID 70 Air inlet heater driver #1 page 127 729 -/- 3, 4, 5
MID 128, SID 211 Sensor Supply Voltage #2 (+5V - 9.3/- 3, 4
DC) page 129
47701632 10-2012 © AB VOLVO PENTA 215

39-0 General
Caption SPN Flashcode FMI

Electrical fault /
value fault
MID 128 / 144, SID 231 SAE J1939 data link page 130 639 6.5/- (EMS) 2
6.4/- (CIU)
MID 128, SID 232 5 V supply page 131 620 9.3/- 3, 4
MID 128, SID 240 Program memory page 132 639 9.9/- 2, 7, 11, 14
MID 128, SID 250 SAE J1708/J1587 data link page 133 608 9.2/- 12
MID 128 / 144, SID 253 Calibration memory 630 9.9/- (EMS) 2, 12, 14
EEPROM page 134 9.8/- (CIU)
MID 128 / 144, SID 254 Controller 1 page 135 629 9.9/- (EMS) 3, 8, 12
9.8/- (CIU)
MID 128, PSID 201 Data link, MID144 page 136 639/1675 -/- 9
216 47701632 10-2012 © AB VOLVO PENTA

Alphabetical index
A Checking supply cable, air filter pressure switch.... 152
About this Workshop manual..................................... 2 Checking supply cable, coldstart valve.................. 170
Alternator fault tracing.............................................. 58 Checking supply cable, coolant level switch.......... 155
Checking supply cable, crankcase pressure
C sensor..................................................................... 185
Checking air inlet pressure sensor......................... 151 Checking supply cable, fuel sensor........................ 138
Checking air inlet temperature sensor.................... 160 Checking supply cable, inlet manifold pressure
Checking air pressure switch................................. 152 sensor..................................................................... 150
Checking camshaft sensor..................................... 175 Checking supply cable, oil pressure sensor........... 144
Checking camshaft sensor wiring........................... 174 Checking supply cable, piston cooling oil tem-
Checking CAN bus cable....................................... 181 perature switch....................................................... 168
Checking coolant level switch................................ 155 Checking supply cable, wastegate valve................ 179
Checking coolant temperature sensor.................... 153 Checking supply cable, water in fuel switch........... 142
Checking crankcase pressure sensor.................... 156 Checking the CAN bus cable................................. 183
Checking exhaust gas temperature sensor............ 161 Checking the charging system................................. 57
Checking flywheel sensor....................................... 177 Checking the injector wiring................................... 173
Checking flywheel sensor wiring............................ 176 Checking the sensor cable for open circuit or
Checking fuel pressure sensor............................... 141 shortcircuit.............................................. 149, 154, 159
Checking IEGR coil................................................ 168 Checking the signal cable for interruption or
Checking IEGR solenoid........................................ 169 shortcircuit.............................................................. 140
Checking IEGR wiring............................................ 174 Checking the starter motor voltage.......................... 56
Checking inlet manifold temperature sensor.......... 150 Checking the wastegate valve................................ 180
Checking negative cable, air filter pressure switch 165 Checking the wiring................................................ 138
Checking negative cable, air filter temperature Checking water in fuel switch................................. 143
switch..................................................................... 158 Component description............................................ 45
Checking negative cable, coldstart valve............... 171 Component location................................................. 32
Checking negative cable, coolant level switch....... 155
Checking negative cable, coolant temperature D
switch..................................................................... 167 Design and Function................................................ 28
Checking negative cable, crankcase pressure E
sensor..................................................................... 184 Electrical System........................................................ 5
Checking negative cable, exhaust gas temper- Electrical Welding..................................................... 52
ature sensor........................................................... 161 EMS 2 (Engine Management System)..................... 28
Checking negative cable, fuel sensor..................... 139 Engine Control Unit (ECU), Replace........................ 53
Checking negative cable, inlet manifold pres- Engine Protection Map............................................... 7
sure/temperature sensor........................................ 148 F
Checking negative cable, oil pressure sensor........ 145 Fault Codes.............................................................. 64
Checking negative cable, oil temperature switch... 162 Fault Tracing............................................................ 62
Checking negative cable, piston cooling oil tem- Fault tracing of cables and connectors..................... 62
perature switch....................................................... 167
Checking negative cable, wastegate valve............ 178 G
Checking negative cable, water in fuel switch........ 143 General................................................... 2, 28, 62, 215
Checking oil level sensor........................................ 144 General advice......................................................... 61
Checking oil pressure sensor................................. 146 I
Checking oil temperature sensor............................ 164 Index....................................................................... 215
Checking preheater relay....................................... 181
M
Checking signal cable voltage, inlet manifold
Malfunctions............................................................. 60
(pressure/)temperature sensor............................... 147
Manual fault tracing in bus cables............................ 59
Checking signal cable, air filter temperature switch 157
MID 128 / 144, PPID 132 Throttle calibrated
Checking signal cable, coolant temperature switch 166
position................................................................... 112
Checking signal cable, crankcase pressure sensor 184
MID 128 / 144, PPID 4 Starter input sensor........... 103
Checking signal cable, exhaust gas tempera-
MID 128 / 144, SID 231 SAE J1939 data link........ 130
ture sensor............................................................. 160
MID 128 / 144, SID 253 Calibration memory
Checking signal cable, inlet manifold pressure
EEPROM................................................................ 134
sensor..................................................................... 151
MID 128 / 144, SID 254 Controller 1...................... 135
Checking signal cable, oil pressure sensor............ 145
MID 128, PID 100 Engine oil pressure..................... 73
Checking signal cable, oil temperature switch....... 163
MID 128, PID 105 Intake manifold temperature....... 76
Checking starter motor relay.................................. 164
MID 128, PID 106 Air inlet pressure......................... 78
Checking stop signal cable between ECU and
MID 128, PID 107 Air filter pressure drop ............... 81
CIU/DCU................................................................ 165
47701632 10-2012 © AB VOLVO PENTA 217

MID 128, PID 108 Barometric pressure................... 84
MID 128, PID 110 Engine coolant temperature........ 85
MID 128, PID 111 Coolant level............................... 88
MID 128, PID 153 Crankcase pressure.................... 90
MID 128, PID 158 ECU battery potential.................. 93
MID 128, PID 172 Inlet air temperature.................... 94
MID 128, PID 173 Exhaust gas temperature............ 96
MID 128, PID 175 Engine oil temperature................ 98
MID 128, PID 190 Engine speed............................ 100
MID 128, PID 45 Inlet air heater status.................... 64
MID 128, PID 94 Fuel Delivery Pressure................. 66
MID 128, PID 97 Water in fuel indicator................... 69
MID 128, PID 98 Engine oil level.............................. 71
MID 128, PPID 19 Internal EGR Status................. 107
MID 128, PPID 3 Starter Output............................. 101
MID 128, PPID 332 Thermostat............................. 114
MID 128, PPID 55 ECU temperature..................... 110
MID 128, PPID 6 Key off input sensor.................... 104
MID 128, PPID 8 Piston Cooling Oil Pressure....... 105
MID 128, PPID 98 Engine sync acknowledge........ 111
MID 128, PSID 201 Data link, MID144................... 136
MID 128, SID 1/2/3/4/5/6 Injector # 1-6.................. 116
MID 128, SID 21 Engine position........................... 120
MID 128, SID 211 Sensor Supply Voltage #2
(+5V DC)................................................................ 129
MID 128, SID 22 Timing sensor, crank.................. 122
MID 128, SID 232 5 V supply................................. 131
MID 128, SID 240 Program memory...................... 132
MID 128, SID 250 SAE J1708/J1587 data link....... 133
MID 128, SID 32, Wastegate output driver............. 124
MID 128, SID 70 Air inlet heater driver #1.............. 127
N
No fault code.......................................................... 137
P
Programming an empty control unit......................... 55
R
Repair Instructions................................................... 52
Repair instructions...................................................... 3
Reprogramming a control unit.................................. 54
S
Safety Instructions.................................................... 23
Special Service Tools............................................... 27
Specifications, Electrical............................................. 5
T
Technical Data........................................................... 5
Trimming the injector.............................................. 172
V
Vodia logging throttle signal................................... 185
W
Wiring Diagrams..................................................... 186
218 47701632 10-2012 © AB VOLVO PENTA

References to Service Bulletins
Group No. Date Refers to
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Signed:.................................................................................
AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Göteborg
Sweden
47701632 English 10–2012

Workshop Manual: Group 30 Electrical System I

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Workshop Manual I

Group 30 Electrical system 5(0)

9L, 12L, 13L, 16L

Safety and Other Instructions

General, Complete Vehicle Software

Cables and fuses

47701632 10-2012 © AB VOLVO PENTA 1

Volvo Penta accepts no responsibility for damage or

2 47701632 10-2012 © AB VOLVO PENTA

Above all, when working on fuel systems, hydraulic

47701632 10-2012 © AB VOLVO PENTA 3

Lock nuts Anaerobic agents.

4 47701632 10-2012 © AB VOLVO PENTA

03-3 Specifications, Electrical

Sensor, fuel pressure

Speed sensor, crankshaft / camshaft

Sensor, oil pressure

Combination sensor, air inlet pressure / inlet manifold temperature

Sensor, coolant temperature

47701632 10-2012 © AB VOLVO PENTA 5

Switch, coolant level

Sensor, crankcase pressure

Combination sensor, oil level / temperature

Switch, piston cooling pressure

Combination sensor, air filter pressure/temperature

6 47701632 10-2012 © AB VOLVO PENTA

Engine Protection Map

Parameter Alarm Engine protection

47701632 10-2012 © AB VOLVO PENTA 7

TAD950VE, TAD951VE, TAD952VE

Parameter Alarm Engine protection

1. Off = No shutdown, alarm only.

8 47701632 10-2012 © AB VOLVO PENTA

Parameter Alarm Engine protection

47701632 10-2012 © AB VOLVO PENTA 9

TAD1250VE, TAD1251VE, TAD1252VE

Parameter Alarm Engine protection

10 47701632 10-2012 © AB VOLVO PENTA

TAD1341GE, TAD1342GE, TAD1343GE,

Parameter Alarm Engine protection

47701632 10-2012 © AB VOLVO PENTA 11

Parameter Alarm Engine protection

1. Off = No shutdown, alarm only.

12 47701632 10-2012 © AB VOLVO PENTA

TAD1351GE, TAD1352GE, TAD1353GE,

Parameter Alarm Engine protection

47701632 10-2012 © AB VOLVO PENTA 13

TAD1340VE, TAD1341VE, TAD1342VE,

Parameter Alarm Engine protection

1. Off = No shutdown, alarm only.

14 47701632 10-2012 © AB VOLVO PENTA

TAD1360VE, TAD1361VE, TAD1362VE,

Parameter Warning level Alarm level Engine protection

1. Off = Disables the function, i.e. no shutdown.

47701632 10-2012 © AB VOLVO PENTA 15

Parameter Warning Alarm level Engine protection

Oil temperature 125 °C 127 °C 127 °C 130 °C N/A

16 47701632 10-2012 © AB VOLVO PENTA

TAD1641VE, TAD1642VE, TAD1643VE

Parameter Alarm Engine protection

1. Off = No shutdown, alarm only.

47701632 10-2012 © AB VOLVO PENTA 17

Parameter “Yellow “Red Derate 0 % to Derate 70 % Forced Forced shut-