Workshop Manual: Group 30 Electrical System E

 

Workshop Manual Group 30 Electrical system

E 2(0)

  D9, D11, D12, D13, D16 Marine Engines (EMS 2)

 

Table of Content General Information 00-0 General ............................................................................................. 2

Specifications 03-3 Specifications, Electrical ................................................................ 5 Switches and Senders ......................................................................... 5 Engine Protection Map ........................................................................ 9

Safety and Other Instructions 05-1 Safety Instructions ........................................................................ 26

Special tools 08-2 Special Service Tools ................................................................... 30

General, Complete Vehicle Software 30-0 General ........................................................................................... 32 Design and Function ......................................................................... 32 30-2 Fault Tracing ................................................................................. 74 Fault Codes ........................................................................................ 74 Measurements .................................................................................. 155

Cables and fuses

37-0 Wiring Diagrams ......................................................................... 196

Miscellaneous 39-0 General ......................................................................................... 197 Index ......................................................................................................... 201 References to Service Bulletins ............................................................ 203

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00-0 General About this Workshop manual General information

Certified engines

This Service Manual contains technical data, descriptions and maintenance and repair instructions for standard model Volvo Penta products. A list of  these products may be found in the section

When carrying out service and repair on emission-certified engines, it is important to be aware of the following:

Specifications.. Specifications

Certification means that an engine type has been inspected and approved by the relevant authority. The engine manufacturer guarantees that all engines of the same type are manufactured to correspond to the certified engine. This places special demands on service and repair  work, namely:

The product designation and the serial number and specification is indicated on the engine decal or type plate. This information must be included in all correspondence regarding the product. The service manual is produced primarily for the use of Volvo Penta workshops and their qualified personnel. It is assumed that any person using the Service Manual has a fundamental knowledge of the product and is able to carry out mechanical and electrical work to trade standard. Volvo Penta continually develops its products; we therefore reserve the right to make changes. All information in this manual is based on which product which was available up to the date on thedata manual was printed. New working methods and significant changes introduced to the product after  this date are communicated in the form of Service bulletins.. bulletins

Spare Parts Spare parts for the electrical and fuel systems are subject to various national safety standards. Volvo Penta Original Spare Parts meet these standards. No damage of any kind caused by the use of spare parts not approved by Volvo Penta will be compensated by any warranty undertaking.

•

Main Mainten tenan ance ce a and nd s serv ervic ice e inter interva vals ls recommended by Volvo Penta must be complied with.

•

Only Only spare spare parts parts ap appro proved ved by Volv Volvo o Pe Penta nta may be used.

•

Servic Service e on inject injection ion pum pumps, ps, p pump ump set settin tings gs a and nd injectors must always be carried out by an

•

authorized Volvo Penta workshop. The eng engine ine mus mustt no nott be convert converted ed or or mo modif dified ied,, except with accessories and service kits which Volvo Penta has approved for the engine.

•

No chan changes ges to tthe he exha exhaust ust pipe and engi engine ne a air  ir  inlet duct installations may be made.

•

No warrant warranty ys seals eals (where (where present present on the product) may be broken by unauthorized persons.

The general instructions in the Operator's Manual concerning operation, service and maintenance apply. 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.

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00-0 General

Repair instructions Introduction

Our Mutual Responsibility

The working methods described in this manual are based on a workshop scenario where the product is mounted in a workholding fixture. Maintenance work is often carried out in situ, in which case - if nothing else is indicated - using the same working methods as the workshop.

Each product comprises a large number of interacting systems and components. A deviation from the technical specification may dramatically increase the environmental impact of an otherwise reliable system. It is therefore critical that the stated wear  tolerances be adhered to, that systems which can be

Warning symbols that occur in the service manual. For significance, refer to Safety Information. Information.

adjusted be correctly set The up and that only Volvo Penta Original Parts are used. intervals in the care and maintenance schedule must be followed. Some systems, e.g. fuel systems, often require special expertise and test equipment. A number of  components are factory-sealed, for among other  things environmental reasons. Warranty-sealed components may not be worked on without authorization to perform such work.

 DANGER!  WARNING!  CAUTION! IMPORTANT!,, NOTE! IMPORTANT! are by no means comprehensive since not everything can be foreseen as service work is carried out in the most varied of circumstances. We call attention to risks that may occur due to incorrect handling during work in a well-equipped workshop using working

Remember that most chemical products, incorrectly used, are harmful to the environment. Volvo Penta recommends the use of biodegradable degreasers whenever components are cleaned, unless otherwise specified in the Service Manual. When working outdoors, take especial care to ensure that oils and

methods and tools tried and tested by us. The service manual describes work operations carried out with the aid of Volvo Penta Special Tools, where such have been developed. Volvo Penta Special Tools are designed to ensure the safest and most rational working methods possible. It is therefore the responsibility of anyone using tools or  working methods other than those we recommend to ensure that no risk of personal injury or mechanical damage is present, or that malfunction can result.

wash residues etc. are correctly properly for  destruction.

In some cases, special safety regulations and user  instructions may be in force for the tools and chemicals mentioned in the Service Manual. These rules must always be observed, so there are no special instructions about this in the workshop manual. By following these basic recommendations and using common sense it is possible to avoid most of the risks involved in the work. A clean workplace and a clean product will eliminate many risks of personal injury and malfunction.

Tightening torque Tightening torques for vital fasteners that must be applied using a torque wrench are indicated in the Service Manual, chapter Tightening torques and torques and in the Manual's work descriptions. All torque indications apply to clean threads, bolt heads and mating faces. Indicated torque data apply to lightly-oiled or dry threads. If lubricants, locking fluids or sealants are required for fasteners, the correct type will be indicated in the job description.

Torque, angle tightening When torque/angle tightening, the fastener is tightened to a specified torque, and tightening then continues through a pre-determined angle. Example: For 90° angle tightening, the fastener is turned an additional 1/4 turn in one sequence, after  the 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 importance that dirt and foreign objects are kept away, as malfunctions or shortened service intervals may otherwise result.

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00-0 General

Lock nuts Removed lock nuts may not be re-used; they must be replaced by new ones, as locking properties are impaired or lost with re-use. In the case of lock nuts with plastic inserts, the tightening torque indicated must be reduced if the nut has the same nut height as a standard, all-metal hexagonal nut. Reduce the torque by 25% for bolt sizes of 8 mm or  larger. In the case of lock nuts with plastic inserts with a high nut-height (where the all-metal thread is as high as a standard hexagonal nut), the indicated torque applies.

Strength Classes Nuts and bolts are grouped into different strength classes. Their classification is shown by a marking on the bolt head. Markings of a higher number indicate stronger material. For example, a bolt marked 10-9 is stronger than one marked 8-8. For this reason, it is important that when bolted joints are removed they are returned to their original locations on re-assembly. When replacing bolts, check the applicable Spare parts catalog  to  to ensure the correct bolt is used.

Sealing compounds etc. To ensure service work is correctly carried out, it is important that the correct type of sealants and locking fluids are used on joints where such are required. In each service manual section concerned, the sealants used in product manufacture are indicated. The same sealants, or sealants with equivalent properties, must be used for maintenance work.  A service technician should have a basic knowledge of how sealing compounds are handled, and are able to assess the condition of existing seals. Make sure that mating surfaces are dry and free from oil, grease, paint and anti-corrosion agent before applying sealant or locking fluid. Always follow the manufacturer's instructions regarding applicable temperatures, hardening times and such. Two basic types of compound are used: RTV preparations (Room Temperature Vulcanizing). Used most often together with gaskets, e.g. sealing gasket joints, or are brushed on gaskets. RTV sealants are completely visible when the part has been removed. Old RTV sealant must be removed before the component is sealed again. Use denatured alcohol.

4

Anaerobic agents. These agents cure in the absence of air. These preparations are used when two solid components, e.g. two cast components, are fitted together without a gasket. Common uses are also to lock and seal plugs, stud threads, taps, oil pressure monitors etc. Hardened anaerobic preparations are vitreous and for this reason, the preparations are colored to make them visible. Hardened anaerobic preparations are highly resistant to solvents, and old compound cannot be removed. On re-assembly, it is important to carefully degrease and wipe dry components first, before applying new sealant in accordance with the instructions.

Safety regulations for fluorocarbon rubber  Fluorocarbon rubber is a common material in seal rings for shafts, and in O-rings, for example. When fluorocarbon rubber is exposed to high temperatures (above 300°C/572°F), hydrofluoric acid can form. This is highly corrosive. Contact with the skin can result in severe chemical burns. Splashes in your eyes can result in corrosive wounds. If you breathe in the fumes, your lungs can be permanently damaged.

 WARNING! Seals must never be cut with a torch, or be burnt afterwards in an uncontrolled manner. Risk for  poisonous gases.

 WARNING!  Always use chloroprene rubber gloves (gloves for  chemicals handling) and goggles. Handle the removed seal in the same way as corrosive acid. All residue, including ash, can be highly corrosive. Never  use compressed air to blow clean. Put the remains in a plastic container, seal it and apply a warning label. Wash the gloves under running water before removing them. The following seals are most probably made from fluorocarbon rubber: Seal rings for the crankshaft, camshaft, idler shafts. O-rings, regardless of where they are installed. Orings for cylinder liner sealing are almost always made of fluorocarbon rubber. Please note that seals which have not been exposed to high temperature can be handled normally.

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03-3 Specifications, Electrical

03-3 Specifications, Electrical Switches and Senders Switch, water in fuel Voltage

12 / 24 V

Connector

3 pin or 2 pin

Contact type

Closes when water is detected

Sensor, fuel pressure Voltage

5V

Connector

3 pin

Working range, pressure

0–700 kPa (0–7 bar / 0–102 PSI)

Pressure signal

0.5–4.5 V

Working range, temperature

-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear

Max. tightening torque

30 ±5 Nm (22.1 ±3.7 lbf.ft.)

 

Camshaft sensor / flywheel sensor  Connector

2 pin

Working range, temperature

-40 °C to +130 °C (-40 °F to +266 °F)

Type

Inductive sensor

Max. tightening torque

8 ±2 Nm (5.9 ±1.5 lbf.ft.)

 

Combined sensor (D9, D11, D12), oil pressure / oil temperature (engine) Voltage

5V

Connector

4 pin

Working range, pressure

0–700 kPa (0–7 bar / 0–102 PSI)

Pressure signal

0.5–4.5 V

Working range, temperature

-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear/NTC

Max. tightening torque

30 ±5 Nm (22.1 ±3.7 lbf.ft.)

Combined sensor (D13, D16), oil level / oil temperature (engine) Voltage

5V

Connector

4 pin

Working range, temperature

-40 °C to +140 °C (-40 °F to +284 °F)

Type

NTC

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03-3 Specifications, Electrical

Combined sensor, oil pressure / oil temperature (transmission) Voltage

5V

Connector

4 pin

Working range, pressure

0–3 MPa (0–30 bar / 0–435 PSI)

Pressure signal

0.5–4.5 V

Working range, temperature

-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear/NTC

Combined sensor (D9, D11, D12, D16), inlet air pressure / intake manifold temperature Voltage

5V

Connector

4 pin

Working range, pressure

40–400 kPa (0.4–4 bar / 5.8–58 PSI)

Pressure signal

0.5–4.5 V

Working range, temperature

-40 °C to +125 °C (-40 °F to +257 °F)

Type

Linear/NTC

Combined sensor (D13), inlet air pressure / intake manifold temperature Voltage

5V

Connector

4 pin

Working range, pressure

50–600 kPa (0.5–6 bar / 7.3–87 PSI)

Pressure signal Working range, temperature

0.5–4.5 V -40 °C to +125 °C (-40 °F to +257 °F)

Type

Linear/NTC

Sensor, coolant temperature Voltage

5V

Connector

2 pin

Working range, temperature

-40 °C to +150 °C (-40 °F to +302 °F)

Type

NTC

Max. tightening torque

28 Nm (20.7 lbf.ft)

Sensor, crankcase pressure Voltage

5V

Connector

3 pin

Working range, pressure

40–140 kPa (0.4-1.4 bar / 5.8-20.3 PSI)

Pressure signal

0.5–4.5 V

Working range, temperature

-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear

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03-3 Specifications, Electrical

Sensor, seawater pressure Voltage

5V

Connector

3 pin

Working range, pressure

0–300 kPa (0-3 bar / 0-43.5 PSI)

Pressure signal

0.5–4.5 V

Working range, temperature

-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear

Sensor, coolant pressure

 

Voltage

5V

Connector

3 pin

Working range, pressure

0–300 kPa (0-3 bar / 0-43.5 PSI)

Pressure signal

0.5–4.5 V

Working range, temperature

-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear

 

Sensor, piston cooling pressure Voltage

5V

Connector

3 pin

Working range, pressure

0–700 kPa (0–7 bar / 0–102 PSI)

Pressure signal Working range, temperature

0.5–4.5 V -40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear

Max. tightening torque

25 ±3 Nm (18.4 ±2.2 lbf.ft.)

 

Switch, coolant level Connector

2 pin

Contact type

Closing for low coolant level

Switch, piston cooling pressure Connector

2 pin

Contact type

Closing for low piston cooling pressure

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03-3 Specifications, Electrical

Switch, oil level (D9, D12) Connector

2 pin

Contact type

Closing for low oil level

Wastegate valve Operational voltage

20–32 V

Connector

2 pin

Working range, pressure

0–300 kPa (0-3 bar / 0-43.5 PSI)

Pressure signal Working range, temperature

0.5–4.5 V -30 °C to +130 °C (-22 °F to +266 °F)

Coil resistance

90 ± 4.5 Ω at 20 °C (68 °F)

Alternator  Voltage

14 / 28 V

Connector

2 pin

Capacity

115 A at 14 V / 80 A at 28 V

Starter motor  Voltage

12 / 24 V

Connector

2 pin

Capacity (applies to D9)

5.5 kW at 12/24 V

Capacity (applies to D11)

5.5 kW at 24 V

Capacity (applies to D12, D13)

6.0 kW at 24 V

Capacity (applies to D16)

7.0 kW at 24 V

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03-3 Specifications, Electrical

Engine Protection Map Engine protection maps are not updated. For the latest version, please refer to the Volvo Penta Sales Support Tool.

D9 Propulsion Sensors Control and monitoring system

Switches Engine Shutdown System

Signal

Range

Warning Initial Delay / Warning Delay

Warning level

Derating level

Shutd. Initial Delay / Shutd. Delay

Shutdow n level (Toleranc e)

Air inlet pressure

0.5-4.5 V

50-400 kPa (7-58 psi)

30 sec from start / 3 sec

325 kPa (425 kPa absolute) (47 psi (62 psi abs.))

335 kPa (49 psi) 50% derating.

NA

NA

Intake manifold temperature

50-0 Ω

-40 - 130 °C ±4%

90 sec from start / 2 sec

80 °C (176 °F)

90 °C (194 °F)

NA

NA

Sensors

(-40 - 266 °F ±4%)

Soft derate.

Coolant level switch

Digital

ON/OFF

30 sec from start / 10 sec

Low (On / Closed)

NA

NA

NA

Coolant temperature

50-0 Ω

-40 - 140 °C ±1.5% (-40 - 284 °F ±1.5%)

30 sec from start / 3 sec

98 °C (208.4 °F)

101 °C (213.8 °F) Soft derate.

1 sec

105 ±2 °C SDU Ch. S1 (221 ±3.6 °F SDU Ch. S1)

NA

NA

NA

Rapid pressure increase

75% derating, 100 rpm

NA

NA

Engine speed,

Freque

-

Instant

Lost signal

NA

NA

NA

camshaft Engine speed, crankshaft

ncy Freque ncy

-

Instant

Lost signal

NA

NA

NA

Eng. overspeed SDU 1800+15%

Freque ncy

54 puls./rev.

Instant

Lost signal

NA

Instant

2070 / 1863 Hz (-1 to 0%)

Eng. overspeed SDU 2200+15%

Freque ncy

54 puls./rev.

Instant

Lost signal

NA

Instant

2530 / 2277 Hz (-1 to 0%)

Exhaust gas temperature after turbine

PT200

0-850 °C ±2.5% (0-1562 °F ±2.5%)

30 sec from start / 1.5 sec

600 °C (1112 °F)

620 °C (1148 °F) Soft derate.

NA

NA

Oil level sensor 

Digital

ON/OFF

30 sec from

Low level

NA

NA

NA

Crankcase pressure

start / 5 sec

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03-3 Specifications, Electrical

Sensors Control and monitoring system

Switches Engine Shutdown System

Sensors

Signal

Range

Warning Initial Delay / Warning Delay

Warning level

Derating level

Shutd. Initial Delay / Shutd. Delay

Shutdow n level (Toleranc e)

Oil temperature

50-0 Ω

-40 - 140 °C (-40 - 284 °F

30 sec from start / 2 sec

125 °C (257 °F)

128 °C (262.4 °F) Soft derate.

NA

NA

Piston cooling switch

Digital

ON/OFF

120 kPa (17.4 psi) 70% derating (20% per  sec)

NA

NA

Water in fuel switch

Digital

ON/OFF

NA

NA

NA

Instant after   120 ±20 kPa 1000 rpm (17.4 ±2.9 psi)

Always

Water in fuel

D9 Propulsion Sensors (rpm Signal dependent)

Range

Initial Delay / Delay

0.5-4.5 V

0-300 kPa ±3% (0-43.5 psi ±3%)

-

0 rpm

500 rpm

1000 rpm

1800 rpm

2200 rpm

-

Warning level

-

-

30 sec from start / 2 sec

0

0

20 (2.9)

50 (7.3)

70 (10.2)

-

Derating level

-

-

10% trq. decr./sec

0

0

10 (1.5)

40 (5.8)

60 (8.7)

-

Differential oil Differential pressure

NA

NA

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-

NA

NA

NA

NA

NA

NA

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

0-700 kPa ±1.5% (0-102 psi ±1.5%)

-

0 rpm

600 rpm

1000 rpm

1800 rpm

2200 rpm

-

Coolant Pressure

Fuel pressure 0.5-4.5 V

Warning Level / Derating Level / Shutdown Level Rpm map, kPa (psi)

Switches Shutdown System

Warning level

-

-

30 sec from start / 5 sec

100 (14.5)

100 (14.5)

150 (21.8)

250 (36.3)

250 (36.3)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

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03-3 Specifications, Electrical

Sensors (rpm Signal dependent)

Range

Initial Delay / Delay

Warning Level / Derating Level / Shutdown Level Rpm map, kPa (psi)

Oil pressure

0.5-4.5 V

0-700 kPa ±1.5% (0-102 psi ±1.5%)

-

Warning level

-

-

30 sec from start / 1 sec

Derating level

-

-

10% trq. decr./sec

Shutdown level (Shutd. Unit Ch. S3)

Digital

ON/OFF

11 sec ±20% from start / 1 sec

NA

Seawater  pressure

0.5-4.5 V

0-300 kPa ±3% (0-44 psi ±3%)

-

Warning level

-

-

Derating level

-

Rev. gear  pressure

Switches Shutdown System

1000 rpm

1800 rpm

2300 rpm

-

-100 170 (-14.5) (24.7)

200 (29.0)

225 (32.6)

250 (36.3)

-

-120 (21.8) 150 (-17.4)

180 (26.1)

205 (29.7)

205 (29.7)

-

NA

120 +20 (17.4 +2.9)

120 +20 (17.4 +2.9)

120 +20 (17.4 +2.9)

Shutdown Unit Setting Run detect. S2, S3: 510 rpm ±2% 459 Hz ±2%, 54 puls./rev.

0 rpm

600 rpm

1400 rpm

1700 rpm

1900 rpm

-

30 sec from start / 2 sec

0

5 (0.7)

10 (1.4)

15 (2.2)

20 (2.9)

-

-

NA

NA

NA

NA

NA

NA

-

-

-

-

0 rpm

600 rpm

1300 rpm

1500 rpm

1800 rpm

-

Warning level

NA

NA

NA

NA

NA

NA

NA

NA

-

Derating level

NA

NA

NA

NA

NA

NA

NA

NA

-

Digital

ON/OFF

11 sec ±20% from start / 1 sec

NA

400 +20 (58.0 +2.9)

400 +20 (58.0 +2.9)

400 +20 (58.0 +2.9)

400 +20 (58.0 +2.9)

Shutdown Unit Setting Run detect. S2, S3: 510 rpm ±2% 459 Hz ±2%, 54 puls./rev.

Shutdown level (Shutd. Unit Ch. S2)

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0 rpm

500 rpm

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03-3 Specifications, Electrical

D9 MG Sensors Control and monitoring system Sensors

Switches Engine Shutdown System

Signal

Range

Warning Initial Delay / Warning Delay

Warning level

Derati ng level

Shutd. Initial Delay / Shutd. Delay

Shutdow n level (Toleranc e)

Air inlet pressure

0.5-4.5 V

50-400 ±4.2 kPa (7-58 ±0.6 psi)

30 sec from start / 3 sec

325 kPa (425 kPa absolute) (47 psi (62 psi abs.))

NA

NA

NA

Intake manifold temperature

50 50-0 -0 Ω

-40 -40 - 13 130 0 °°C C ±4% ±4% (-40 - 266 °F ±4%)

90 sec from start / 2 sec

80 °C (176 °F)

NA

NA

NA

Coolant level switch

Digital

ON/OFF

30 sec from start / 10 sec

Low (On / Closed)

NA

NA

NA

Coolant temperature

50-0 Ω

-40 - 140 °C ±1.5% (-40 - 284 °F ±1.5%)

30 sec from start / 3 sec

98 °C (208.4 °F)

NA

1 sec

105 ±2 °C SDU Ch. S1 (221 ±3.6 °F SDU Ch. S1)

Engine speed, camshaft

Freque ncy

-

Instant

Lost signal

NA

NA

NA

Engine speed, crankshaft

Freque ncy

-

Instant

Lost signal

NA

NA

NA

Eng. overspeed SDU 1500+15%

Freque ncy

54 puls./rev.

Instant

Lost signal

NA

Instant

1725 / 1553 Hz (-1 to 0%)

Eng. overspeed SDU 1800+15%

Freque ncy

54 puls./rev.

Instant

Lost signal

NA

Instant

2070 / 1863 Hz (-1 to 0%)

Exhaust gas temperature after turbine

PT200

600 °C (1112 °F)

NA

NA

NA

Oil level sensor 

Digital

ON/OFF

3 0 se/c5frsec om start

Low level

NA

NA

NA

Oil temperature

50-0 Ω

-40 - 140 °C (-40 - 284 °F

30 sec from start / 2 sec

125 °C (257 °F)

NA

NA

NA

Piston cooling switch

Digital

ON/OFF

NA

NA

NA

Water in fuel switch

Digital

ON/OFF

NA

NA

NA

12

0-850 °°C C ±2 ±2.5% 30 sec from (0-1562 °F ±2.5%) start / 1.5 sec

Instant after   120 ±20 kPa 1000 rpm (17.4 ±2.9 psi) Always

Water in fuel

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03-3 Specifications, Electrical

D9 MG Sensors (rpm Signal dependent)

Range

Initial Delay / Delay

0.5-4.5 V

0-300 kPa ±3% (0-43.5 psi ±3%)

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-

30 sec from start / 2 sec

0

0

20 (2.9)

50 (7.3)

70 (10.2)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

NA

NA

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-

NA

NA

NA

NA

NA

NA

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

0-700 kPa ±1.5% (0-102 psi ±1.5%)

-

0 rpm

600 rpm

1000 rpm

1600 rpm

1800 rpm

-

Coolant Pressure

Differential oil Differential pressure

Fuel pressure 0.5-4.5 V

Warning Level / Derating Level / Shutdown Level Rpm map, kPa (psi)

Switches Shutdown System

Warning level

-

-

30 sec from start / 5 sec

0

100 (14.5)

200 (29.0)

300 (43.5)

300 (43.5)

-

Derating level Oil pressure

0.5-4.5 V

0-700 kPa ±1.5% (0-102 psi ±1.5%)

NA -

NA 0 rpm

NA 500 rpm

NA 1000 rpm

NA 1800 rpm

NA 2300 rpm

-

Warning level

-

-

30 sec from start / 1 sec

0

160 (23.2)

200 (29.0)

225 (32.6)

250 (36.3)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

Shutdown level (Shutd. Unit Ch. S3)

Digital

ON/OFF

11 sec ±20% from start / 1 sec

NA

NA

120 +20 (17.4 +2.9)

120 +20 (17.4 +2.9)

120 +20 (17.4 +2.9)

Shutdown Unit Setting Run detect. S2, S3: 800 rpm ±2% 720 Hz ±2%,

Seawater  pressure

0.5-4.5 V

0-300 kPa ±3% (0-44 psi ±3%)

-

0 rpm

600 rpm

1400 rpm

1700 rpm

1900 rpm

Warning level

-

-

30 sec from start / 2 sec

0

5 (0.7)

10 (1.4)

15 (2.2)

20 (2.9)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

47700583

 08  08-2017 © AB VOLVO PENTA

54 puls./rev. Only HE and KC

13

 

03-3 Specifications, Electrical

D11 Propulsion Derate to engine protection map Parameter

“Yellow lamp”

“Red lamp”

Derating

High coolant temperature

98 °C (208 °F)

101 °C (213.8 °F)

101 °C (213.8 °F) –0% 103 °C (217.4 °F) –25% 106 °C (222.8 °F) –50%

High oil temperature

120 °C (248 °F)

122 °C (251.6 °F)

122 °C (251.6 °F) –0% 124 °C (255.2 °F) –50% 126° (258.8 °F) –70% 80 °C (176 °F) –0% 85 °C (185 °F) –50% 90 °C (194 °F) –70%

High intake manifold temperature

75 °C (167 °F)

80 °C (176 °F)

High air inlet pressure

27 270 0 kP kPa ((39 39.2 .2 PSI) PSI)

28 280 0 kP kPa ((40 40.6 .6 PSI) PSI)

>28 280 0 kPa kPa (40. (40.6 6P PSI SI)) – –50 50% %

Low coolant level

Switch

-

-

Low lube oil pressure Yellow lamp acc. to following: 0 rpm

0 kPa (0 PSI)

500 rpm

160 kPa (23.2 PSI)

1 000 rpm

280 kPa (40.6 PSI)

1500 rpm

320 kPa (46.4 PSI)

2300 rpm

330 kPa (47.9 PSI)

Derate 70% and red lamp on pressures 20 kPa (2.9 PSI) lower than the map value. Piston cooling pressure Only red lamp acc. to following: 0 rpm

0 kPa (0 PSI)

800 rpm

0 kPa (0 PSI)

1000 rpm

75 kPa (10.9 PSI)

1500 rpm

230 kPa (33.4 PSI)

2300 rpm

250 kPa (36.3 PSI)

Derate 75% on pressures lower than the map value.

Crankcase pressure

Red lamp and max. 1200 rpm and 75% derate. Detection: Very rapid and high crankcase pressure increasings.

14

47700583

08-2017 © AB VOLVO PENTA

 

03-3 Specifications, Electrical

D12 Propulsion Sensors Warning / Alarm

Alarm level

Derating level

Condition/delay

Derating

Intake manifold temperature

80 °C (176 °F)

85 °C (185 °F)

-

Soft derate

Coolant temperature

95 °C (203 °F)

98 °C (208.4 °F)

-

-

Crankcase pressure

Rapid pressure increase

-

-

1000 rpm

Oil temperature

125°C (257 °)

128°C (262,4 °F) 128°C (262.4 °F)

-

-

Piston cooling pressure

150 ±20 kPa (21.8 ±2.9 PSI)

150 ±20 kPa (21.8 ±2.9 PSI)

 Above 1300 rpm instant

Yes, 70%

Water in fuel

Water in fuel

-

-

-

Sensors Warning / Alarm

Rpm map

Air inlet pressure

1700 rpm

1900 rpm

2100 rpm

2300 rpm

2360 rpm

-

 Alarm level

450 kPa (65.3 PSI)

440 kPa (63.8 PSI)

430 kPa (62.4 PSI)

395 kPa (57.3 PSI)

390 kPa (56.6 PSI)

-

Derating limit

460 kPa (66.7 PSI) 500 rpm

450 kPa (65.3 PSI) 1800 rpm

440 kPa (63.8 PSI) 2300 rpm

405 kPa (58.7 PSI) -

400 kPa (58.0 PSI) -

Yes, 50% -

 Alarm level

50 kPa (7.3 PSI)

200 kPa (29.0 PSI)

200 kPa (29.0 PSI)

-

-

-

Oil pressure

500 rpm

1000 rpm

1800 rpm

2300 rpm

-

-

 Alarm level

150 kPa (21.8 PSI)

200 kPa (29.0 PSI)

225 kPa (32.6 PSI)

250 kPa (36.3 PSI)

-

-

Derating limit

130 kPa (18.9 PSI)

170 kPa (24.7 PSI)

205 kPa (29.7 PSI)

230 kPa (33.4 PSI)

-

Yes, 70%

Fuel pressure

47700583

Derating

 08  08-2017 © AB VOLVO PENTA

15

 

03-3 Specifications, Electrical

D13 Propulsion Sensors Warning / Alarm

Alarm level

Derating level

Derating

Coolant level

Low (ON / closed)

-

-

Coolant temperature

98 °C (218.4 °F)

101 °C (213.8 °F)

See soft derate 1

Coolant temperature, SDU

N/A

N/A

N/A

Engine speed, camshaft

Lost signal

N/A

N/A

Engine speed, crank Lost signal Engine overspeed SDU 2300 + 15% Lost signal

N/A N/A

N/A N/A

200 °C (392 °F)

See soft derate 2

Exhaust gas temperature (D13B-C/ 560 °C (1040 °F) G)

585 °C (1085 °F)

See soft derate 2

Exhaust gas temperature (D13B-D) 645 °C (1193 °F)

670 °C (1238 °F)

See soft derate 3

Exhaust wet gas temperature

175 °C (347 °F)

Oil level

Low level

N/A

N/A

Oil temperature

130 °C (266 °F)

135 °C (275 °F)

D13B-C/G: soft derate 3 D13B-D: soft derate 4

Piston cooling pressure

N/A

N/A

N/A

Gear oil temperature, EVC (D13BC/G)

95 °C (203 °F)

N/A

N/A

Gear oil temperature, EVC (D13BD)

N/A

N/A

N/A

Gear oil pressure, EVC

700 kPa (101.5 PSI) N/A

N/A

Gear oil pressure, SDU

N/A

N/A

N/A

Intake manifold temperature (D13B-D MP)

80 °C (176 °F)

85 °C (185 °F)

See soft derate 2

Crankcase pressure

N/A

N/A

N/A

Water in fuel

Water In fuel

N/A

N/A

Switches Engine Shutdown System Switches

Range

Shutd.. Initial Delay / Shutd. Delay

Shutdown Level (Tolerance)

Coolant temperature, SDU

ON/OFF

1 sec from start / 1 sec

SDU S1: 105 ±2 °C (221 ±3.6 °F)

Instant

2645 / 6745 Hz (-1 to 0%)

11 sec ±20% from start / 1 sec

400 ±20 kPa (58 ±2.9 psi) Shutdown Unit Setting S2, S3: 510 rpm ±2% 1300 Hz ±2% 153 puls./rev. ±2%

Engine overspeed SDU 2300 + 15% 153 puls./rev. Gear oil pressure, SDU

16

ON/OFF

47700583

08-2017 © AB VOLVO PENTA

 

03-3 Specifications, Electrical

D13 Propulsion Sensors Warning / Alarm / Derating

Rpm map

Air inlet pressure (D13B-C/G R4 800 hp)

600 rpm

1000 rpm

1500 rpm

2000 rpm

2300 rpm

Warning level 0 % load

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

-

Warning level 100 % load

420 kPa (60.9 PSI)

268 kPa (38.9 PSI)

295 kPa (42.8 PSI)

333 kPa (48.3 PSI)

345 kPa (50.0 PSI)

-

Derating level 100 % load

430 kPa (62.4 PSI)

278 kPa (40.3 PSI)

305 kPa (44.2 PSI)

343 kPa (49.7 PSI)

355 kPa (51.5 PSI)

50% diff. between max torque and engine prot. map

Air inlet pressure (D13B-G R5 900 hp)

600 rpm

1000 rpm

1500 rpm

2000 rpm

2300 rpm

Warning level 0 % load

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

-

Warning level 100 % load

420 kPa (60.9 PSI)

322 kPa (611.6 PSI)

335 kPa (635.0 PSI)

356 kPa (672.8 PSI)

366 kPa (690.8 PSI)

-

Derating level

430 kPa

332 kPa

345 kPa

366 kPa

376 kPa

50% diff. between

100 % load

(62.4 PSI)

(629.6 PSI)

(653 PSI)

(690.8 PSI)

(708.8 PSI)

max torque and engine prot. map

Air inlet pressure (D13B-D R3 700hp)

600 rpm

1000 rpm

1500 rpm

2000 rpm

2300 rpm

Warning level

305 kPa (44.2 PSI)

305 kPa (44.2 PSI)

305 kPa (44.2 PSI)

295 kPa (42.8 PSI)

259 kPa (37.6 PSI)

-

Derating level

315 kPa (45.7 PSI)

315 kPa (45.7 PSI)

315 kPa (45.7 PSI)

305 kPa (44.2 PSI)

269 kPa (39.0 PSI)

50% diff. between max torque and engine prot. map

Intake manifold temperature (D13B-C/G)

600 rpm

1000 rpm

1500 rpm

2000 rpm

2300 rpm

Warning level

80 °C (176 80 °C (176 80 °C (176 65 °C (149 65 °C (149 °F) °F) °F) °F) °F)

Derating level

85 °C (185 85 °C (185 85 °C (185 70 °C (158 70 °C (158 See soft derate 4 °F) °F) °F) °F) °F)

Fuel pressure

600 rpm

1000 rpm

1200 rpm

1400 rpm

2300 rpm

Warning level

180 kPa (26.1 PSI)

240 kPa (34.8 PSI)

255 kPa (37.0 PSI)

270 kPa (39.2 PSI)

270 kPa (39.2 PSI)

47700583

Condition

 08  08-2017 © AB VOLVO PENTA

-

17

 

03-3 Specifications, Electrical

Oil pressure (D13B-C/G)

500 rpm

1000 rpm

1500 rpm

2300 rpm

Warning level

120 kPa (17.4 PSI)

200 kPa (29.0 PSI)

265 kPa (38.4 PSI)

265 kPa (38.4 PSI)

-

Derating level

90 kPa (13.1 PSI)

170 kPa (24.7 PSI)

235 kPa (34.1 PSI)

235 kPa (34.1 PSI)

-

N/A

150 ±20 kPa (21.8 ±2.9 PSI)

150 ±20 kPa (21.8 ±2.9 PSI)

Shutdown level (Shutdown N/A Unit Channel S3)

150 ±20 kPa (21.8 ±2.9 PSI)

Shutdown Unit Setting S2, S3: 510 rpm ±2% 1300 Hz ±2% 153 pulses / rev.

Oil pressure (D13B-D)

0 rpm

Warning level Derating level

600 rpm

1000 rpm

1500 rpm

2300 rpm

-100 kPa 120 kPa (-14.5 PSI) (17.4 PSI)

200 kPa (29.0 PSI)

265 kPa (38.4 PSI)

265 kPa (38.4 PSI)

-

-130 kPa 90 kPa (-18.9 PSI) (13.1 PSI)

170 kPa (24.7 PSI)

235 kPa (34.1 PSI)

235 kPa (34.1 PSI)

Shutdown Unit Setting S2, S3: 510 rpm ±2% 1300 Hz ±2%

Shutdown level (Shutdown N/A Unit Channel S3)

N/A

150 ±20 kPa (21.8 ±2.9 PSI)

150 ±20 kPa (21.8 ±2.9 PSI)

150 ±20 kPa (21.8 ±2.9 PSI)

Coolant pressure (D13B-C/D)

0 rpm

600 rpm

1000 rpm

1500 rpm

2300 rpm

Warning level

0 kPa (0.0 PSI)

5 kPa (0.7 PSI)

30 kPa (4.4 PSI)

55 kPa (8.0 PSI)

125 kPa (18.1 PSI)

-

Derating level

-10 kPa (-1.5 PSI)

-5 kPa (-0.7 PSI)

20 kPa (2.9 PSI)

45 kPa (6.5 PSI)

115 kPa (16.7 PSI)

-

Seawater pressure (D13B-C/D)

600 rpm

1000 rpm

1500 rpm

1900 rpm

2300 rpm

Warning level

5 kPa (0.7 PSI)

20 kPa (2.9 PSI)

40 kPa (5.8 PSI)

60 kPa (8.7 PSI)

60 kPa (8.7 PSI)

-

Derating level

-5 kPa (-0.7 PSI)

10 kPa (1.5 PSI)

30 kPa (4.4 PSI)

50 kPa (7.3 PSI)

50 kPa (7.3 PSI)

-

18

47700583

153 pulses / rev.

08-2017 © AB VOLVO PENTA

 

03-3 Specifications, Electrical

Soft derate, D13 1) Soft derate, coolant temp

Spee Sp eed d / °°C C 10 101 1 °°C C (213 (213.8 .8 °F) °F) 103 103 °°C C (217 (217.4 .4 °F) °F) 10 106 6 °C (2 (222 22.8 .8 °F) °F)

Remaining torque

1200 rpm

100 %

100 %

100 %

1800 rpm

100 %

75 %

50 %

2300 rpm

100 %

75 %

50 %

2) Soft derate, exhaust gas temp

Spee peed / °°C C 585° 85°C ((1 1085 °F °F))

590°C (1 (1094 °F)

595°C (1 (11 103 °F)

600°C (1112 °F °F))

D13B-C/G Remaining torque

1200 rpm 1800 rpm

100 % 100 %

100 % 70 %

100 % 60 %

100 % 50 %

2300 rpm

100 %

70 %

60 %

50 %

2) Soft derate, intake manifold temp

Speed / °C 85 °C (185 °F)

90 °C (194 °F)

95 °C (203 °F)

D13B-D Remaining torque

1200 rpm

100 %

96 %

94 %

1800 rpm

100 %

50 %

30 %

2300 rpm

100 %

50 %

30 %

3) Soft derate, oil temp

Spee Sp eed d / °C 13 135 5 °C °C (27 (275 5 °F) °F)

13 137 7 °C °C (27 (278. 8.6 6 °F) °F) 13 139 9 °C °C (28 (282. 2.2 2 °F) °F)

D13B-C/G Remaining torque

600 rpm

100 %

100 %

100 %

1200 rpm

100 %

50 %

30 %

1800 rpm

100 %

50 %

30 %

3) Soft derate, exhaust temp

Spee Sp eed d / °C 67 670 0 °C °C (12 (1238 38 °F °F))

67 675 5 °C °C ((12 1247 47 °F °F))

68 680 0 °C °C (12 (1256 56 °F °F))

68 685 5 °C °C ((12 1265 65 °F °F))

D13B-D Remaining torque

1200 rpm

100 %

98 %

97 %

96 %

1800 rpm

100 %

70 %

60 %

50 %

2300 rpm

100 %

70 %

60 %

50 %

4) Soft derate, intake manifold temp

Speed / °C 70 °C (158 °F) Varvtal

75 °C (167 °F)

80 °C (176 °F)

85 °C (185 °F)

D13B-C/G Remaining torque

1200 rpm

100%

100%

100%

100%

1500 rpm

100%

100%

100%

100%

1800 rpm

100%

100%

60 %

34 %

2000 rpm 2300 rpm

100% 100%

50 % 50 %

30 % 30 %

30 % 30 %

90 °C (194 °F)

95 °C (203 °F)

1200 rpm

100%

100%

1500 rpm

50 %

30 %

1800 rpm

30 %

30 %

2000 rpm

30 %

30 %

2300 rpm

30 %

30 %

4) Soft derate, oil temp

Spee Sp eed d / °C 13 135 5 °C °C (27 (275 5 °F) °F)

13 137 7 °C °C (27 (278. 8.6 6 °F) °F) 13 139 9 °C °C (28 (282. 2.2 2 °F) °F)

D13B-D Remaining torque

1200 rpm

100 %

100 %

100 %

1800 rpm

100 %

50 %

30 %

2300 rpm

100 %

50 %

30 %

47700583

 08  08 2017 © AB VOLVO PENTA

19

 

03-3 Specifications, Electrical

D16 Propulsion Sensors Control and monitoring system

Switches Engine Shutdown System Shutd. Initial Delay / Shutd. Delay

Shutdo wn level (Toleran ce)

30 sec from 300 kPa (400 310 kPa (45 psi) start / 2.25 sec kPa absolute) (44 psi (58 psi 50% derating. abs.))

NA

NA

-40 - 130 °C ±4% (-40 - 266 °F ±4%)

90 sec from start / 2.25 sec

80 °C (176 °F)

90 °C (194 °F) See soft derate 3.

NA

NA

Digital

ON/OFF

30 sec from start / 7.5 sec

Low (On / Closed)

NA

NA

NA

Coolant temperature

50-0 Ω

-40 - 140 °C ±1.5% (-40 - 284 °F ±1.5%)

30 sec from start / 2.25 sec

98 °C (208.4 °F)

101°C (213.8 °F) See soft derate 1.

1 sec

105 ±2 °C SDU Ch. S1 (221 ±3.6 °F SDU Ch. S1)

Engine speed, camshaft

Freque ncy

-

Instant

Lost signal

NA

NA

NA

Engine speed, crankshaft

Freque ncy

-

Instant

Lost signal

NA

NA

NA

Eng. overspeed SDU 1800+15%

Freque ncy

153 puls./rev.

Instant

Lost signal

NA

Instant

2070 / 5279 Hz (-1 to 0%)

Eng. overspeed

Freque ncy

153 puls./rev.

Instant

Lost signal

NA

Instant

2185 / 5572 Hz

Sensors

Signal

Range

Air inlet pressure

0.5-4.5 V

50-400 kPa (7-58 psi)

Air inlet pressure after turbine

50-0 Ω

Coolant level switch

Warning Initial Delay / Warning Delay

Warning level

Derating level

(-1 to 0%)

SDU 1900+15% Exhaust Temperature

PT200

0-850 °C (0-1562 °F)

30 sec from start / 1 sec

650 °C (1202 °F)

665 °C (1229 °F) See soft derate 4.

NA

NA

Oil level sensor 

Digital

ON/OFF

30 sec from start / 5 sec

Low level

NA

NA

NA

47700583

20

08 2017 © AB VOLVO PENTA

 

03-3 Specifications, Electrical

Sensors Control and monitoring system Sensors

Switches Engine Shutdown System

Signal

Range

Warning Initial Delay / Warning Delay

Warning level

Derating level

Shutd. Initial Delay / Shutd. Delay

Shutdo wn level (Toleran ce)

Oil temperature

50-0 Ω

-40 - 140 °C (-40 - 284 °F

30 sec from start / 1.5 sec

125 °C (257 °F)

128 °C (262.4 °F) See soft derate 2.

NA

NA

Piston cooling switch

Digital

ON/OFF

30 sec from start / 4 sec

120 ±20 kPa (17.4 ±2.9 psi)

120 kPa (17.4 psi) 70% derating.

NA

NA

Rev. gear  temperature

NA

NA

NA

NA

NA

NA

NA

Water in fuel switch

Digital

ON/OFF

Always

Water in fuel

NA

NA

NA

D16 Propulsion

Sensors (rpm Signal dependent)

Range

InitiDelay al Delay /

0.5-4.5 V

0-300 kPa ±3% (0-43.5 psi ±3%)

-

0 rpm

600 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-

30 sec from start / 1.5 sec

0

5 (0.7)

55 (8.0)

100 (14.5)

130 (18.9)

-

Derating level (50% remaining trq.)

-

-

10% trq. decr./sec

-50 (-7.3)

-45 (-6.5)

5 (0.7)

50 (7.3)

80 (11.6)

-

Digital

ON/OFF

11 sec ±20% from start / 1 sec

NA

NA

NA

NA

NA

Shutdown Unit Setting S4: 510 rpm ±2% 1300 Hz ±2%, 153 puls./rev.

NA

NA

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-

NA

NA

NA

NA

NA

NA

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

-

0 rpm

500 rpm

1000 rpm

1800 rpm

1900 rpm

-

Coolant Pressure

Shutd. Level (Shutd. Unit Ch. S4)

Differential oil Differential pressure

Fuel pressure 0.5-4.5 0-700 kPa V (0-102 psi)

WarningShutdown Level / Derating Level Level / Rpm map, kPa (psi)

Switches Shutdown System

Warning level

-

-

30 sec from start / 10 sec

-50 (-7.3)

50 (7.3)

75 (10.9)

200 (29.0)

200 (29.0)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

47700583

 08  08 2017 © AB VOLVO PENTA

21

 

03-3 Specifications, Electrical

Sensors (rpm Signal dependent) Oil pressure

Range

0.5-4.5 0-700 kPa V (0-102 psi)

Initial Delay / Delay -

Warning Level / Derating Level / Shutdown Level Rpm map, kPa (psi) 0 rpm

500 rpm

1000 rpm

1500 rpm

1900 rpm

-

200 (29.0)

250 (36.3)

250 (36.3)

-

Warning level

-

-

Derating level (30%

-

-

10% trq. decr./sec

-10 (-1.5)

140 (20.3)

180 (26.1)

230 (33.4)

230 (33.4)

-

Digital

ON/OFF

11 sec ±20% from start / 1 sec

NA

NA

NA

NA

NA

Shutdown Unit Setting S4: 510 rpm ±2% 1300 Hz ±2%, 153 puls./rev.

0.5-4.5 V

0-300 kPa (0-44 psi)

-

0 rpm

600 rpm

1400 rpm

1700 rpm

1900 rpm

Only HE and KC

Warning level

-

-

30 sec from start / 4 sec

-20 (-2.9)

5 (0.7)

25 (3.6)

35 (5.1)

40 (5.8)

Only HE and KC

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

Rev. gear  pressure

-

-

-

0 rpm

600 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

NA

NA

NA

NA

NA

NA

NA

NA

-

Derating level

NA

NA

NA

NA

NA

NA

NA

NA

-

Shutd. Level (Shutd. Unit Ch. S2)

Digital

ON/OFF

4 sec from start / 1 sec

NA

400 ±20 (58 ±2.9)

400 ±20 (58 ±2.9)

400 ±20 (58 ±2.9)

400 ±20 (58 ±2.9)

Shutdown Unit Setting S2, S3: 510 rpm ±2% 1300 Hz ±2%, 153 puls./rev.

remaining trq.) Shutd. Level (Shutd. Unit Ch. S4)

Seawater  pressure

30 sec from -100 160 start / 0.75 sec (-14.5) (23.2)

Switches Shutdown System

47700583

22

08 2017 © AB VOLVO PENTA

 

03-3 Specifications, Electrical

D16 1) Soft derate, coolant temp

Speed

101 °C (213.8 °F) 103 °C (217.4 °F) 106 °C (222.8 °F)

Remaining torque

600 rpm

100%

100%

100%

1200 rpm

100%

91%

82%

1800 rpm

100%

83%

66%

2) Soft derate, oil temp

Speed

128 °C (262.4 °F) 130 °C (266 °F)

135 °C (275 °F)

Remaining torque

600 rpm

100%

100%

100%

1200 rpm

100%

91%

74%

1800 rpm

100%

83%

52%

3) Soft derate, intake manifold temp.

Speed

90 °C (194 °F)

95 °C (203 °F)

105 °C (221 °F)

Remaining torque

600 rpm

100%

100%

100%

1200 rpm

100%

82%

74%

1800 rpm

100%

66%

52%

4) Soft derate, exhaust temp

Speed

665 °°C C (1 (1229 °F °F)

675°C (1 (1247 °F)

680°C (1 (1256 °F)

685°C ((1 1265 °F)

Remaining torque

600 rpm

100%

100%

100%

100%

1200 rpm

100%

96%

93%

89%

1800 rpm

100%

93%

86%

80%

47700583

 08  08-2017 © AB VOLVO PENTA

23

 

03-3 Specifications, Electrical

D16 MG Sensors Control and monitoring system Sensors

Signal

Range

Air inlet pressure

0.5-4.5 V

50-400 kPa (7-58 psi)

Air inlet pressure after  turbine

50-0 Ω

Coolant level switch

Warning Initial Delay / Warning Delay

Switches Engine Shutdown System Warning level

Deratin g level

Shutd. Initial Delay / Shutd. Delay

Shutdo wn level (Toleran ce)

30 sec from start / 300 kPa (400 2.25 sec kPa absolute) (44 psi (58 psi abs.))

NA

NA

NA

-40 - 130 °C ±4% (-40 - 266 °F ±4%)

90 sec from start / 2.25 sec

80 °C (176 °F)

NA

NA

NA

Digital

ON/OFF

30 sec from start / 7.5 sec

Low (On / Closed)

NA

NA

NA

Coolant temperature

50-0 Ω

-40 - 140 °C ±1.5% (-40 - 284 °F ±1.5%)

30 sec from start / 2.25 sec

98 °C (208.4 °F)

NA

1 sec

105 ±2 °C SDU Ch. S1 221 ±3.6 °F SDU Ch. S1

Engine speed, camshaft

Freque ncy

-

Instant

Lost signal

NA

NA

NA

Engine speed, crankshaft

Freque ncy

-

Instant

Lost signal

NA

NA

NA

Eng. overspeed SDU 1500+15%

Freque ncy

153 puls./rev.

Instant

Lost signal

NA

Instant

1725 / 4399 Hz (-1 to 0%)

Eng. overspeed SDU 1800+15%

Freque ncy

153 puls./rev.

Instant

Lost signal

NA

Instant

2070 / 5279 Hz (-1 to 0%)

Exhaust Temperature

PT200

0-850 °C (0-1562 °F)

30 sec from start / 5 sec

650 °C (1202 °F)

NA

NA

NA

Oil level sensor 

Digital

ON/OFF

30 sec from start / 5 sec

Low level

NA

NA

NA

Oil temperature

50-0 Ω

-40 - 140 °C (-40 - 284 °F

30 sec from start / 2.25 sec

125 °C (257 °F)

NA

NA

NA

Piston cooling switch

Digital

ON/OFF

NA

NA

NA

Water in fuel switch

Digital

ON/OFF

NA

NA

NA

20 sec from start / 120 ±20 kPa 2.25 sec (17.4 ±2.9 psi) NA

Water in fuel

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03-3 Specifications, Electrical

D16 MG Sensors (rpm Signal dependent)

Range

Initial Delay / Delay

0.5-4.5 V

0-300 kPa ±3% (0-43.5 psi ±3%)

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

Shutd. Level (Shutd. Unit Ch. S4)

Digital

ON/OFF

11 sec ±20% from start / 1 sec

NA

NA

NA

NA

NA

Shutdown Unit Setting S4: 800 rpm ±2% 2040 Hz ±2%, 153 puls./rev.

NA

NA

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-

NA

NA

NA

NA

NA

NA

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

-

0 rpm

600 rpm

1000 rpm

1500 rpm

1800 rpm

-

Coolant Pressure

Differential oil Differential pressure

Fuel pressure 0.5-4.5 0-700 kPa V (0-102 psi)

Warning Level / Derating Level / Shutdown Level Rpm map, kPa (psi)

Switches Shutdown System

Warning level

-

-

30 sec from start / 5 sec

-50 (-7.3)

50 (7.3)

75 (10.9)

175 (25.4)

200 (29.0)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1900 rpm

-

250 (36.3)

250 (36.3)

250 (36.3)

-

Oil pressure

0.5-4.5 0-700 kPa V (0-102 psi)

Warning level

-

-

30 sec from -100 150 start / 2.25 sec (-14.5) (21.8)

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

Shutd. Level (Shutd. Unit Ch. S4)

Digital

ON/OFF

11 sec ±20% from start / 1 sec

NA

NA

NA

NA

NA

Shutdown Unit Setting S4: 800 rpm ±2% 2040 Hz ±2%, 153 puls./rev.

Seawater  pressure

0.5-4.5 V

0-300 kPa (0-44 psi)

-

0 rpm

600 rpm

1400 rpm

1700 rpm

1900 rpm

Only HE and KC

Warning level

-

-

30 sec from start / 3.75 sec

-20 (-2.9)

5 (0.7)

25 (3.6)

35 (5.1)

40 (5.8)

Only HE and KC

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

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05-1 Safety Instructions

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 section About this Workshop m manual  anual  and  and Repair  instructions carefully 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, 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 t he product or property. NOTICE! Is used to draw your attention to important information that will facilitate the work or operation in NOTICE! Is progress.

This symbol is used on certain operations to indicate the following: This operation requires prior theoretical and/or instructor led training before attempting. Contact your local training organization for further information.

This symbol is used to inform that added information needs to be read. And where to find needed information.

This symbol is used where VODIA computer is needed,. either for fault tracing, testing or for programming. A compilation of safety precautions that must be taken and risks which must be paid attention to is presented in the following pages.

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05-1 Safety Instructions

!

Immobilize the engine by turning off the power  supply to the engine at the main switch (switches) and lock it (them) in the off position before starting work. Post a warning notice at the main circuit breaker.

!

 Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out and system pressure will be lost. Open the filler cap slowly, and release the pressure in the 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 out with the engine stopped. However, some work, such as adjustments, will require the engine to be running. Approaching an engine which is running is a safety risk. Bear in mind that loose clothing or long hair can fasten in rotating parts and cause serious personal injury.

!

Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before any work is begun. Never start or operate the engine with the oil filler cap removed, because of the risk of oil ejection.

!

Be aware of hot surfaces (exhaust pipes, turbos, charge air pipes, starting heaters etc.) and hot fluids in pipes and hoses on an engine that is running or has just stopped. If work is done adjacent to a running engine, a careless movement or a dropped tool may in the worst case lead to personal injury.

!

Never start the engine without installing the air  filter. The rotating compressor turbine in the turbocharger can cause severe injury. Foreign objects entering the intake ducts can also cause mechanical damage. Install all protective covers before the engine is started.

!

Ensure that the warning symbols or information decals on the product are always clearly visible. Replace decals which have been damaged or  painted over.

!

Only start the engine in a well-ventilated space. When running in a confined space, exhaust fumes and crankcase gases must be led away from the engine bay or workshop area.

!

 Avoid getting oil on your skin! Protracted or  repeated exposure to oil can cause skin to become dry. Irritation, dryness, eczema and other skin problems may then result. From a health standpoint, used oil is more dangerous than new. Use protective gloves and avoid oilsoaked clothes and rags. Wash regularly, especially before eating. Use suitable barrier  creams to counteract drying out of the skin and to aid dirt removal.

!

The majority of chemicals e.g. engine and transmission oils, glycol, gasoline, and diesel oil, together with chemicals for workshop use such as degreasing agents, paints and solvents, are injurious to health. Carefully read the instructions on the product packaging!  Always follow a product's safety directions, e.g. use of protective mask, glasses, gloves etc. Ensure that other personnel are not exposed to substances that are injurious to health. Ensure good ventilation. Handle used and leftover  chemicals in the prescribed manner.

!

Stop the engine and turn off the electrical supply at the main switch(es) before carrying out work on the electrical system.

!

Clutch adjustments must be carried out with the engine stopped.

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05-1 Safety Instructions

!

 Always use protective glasses or goggles when carrying out work where a risk of splinters, grinding sparks, splashes from acid or other  chemicals is present. Your eyes are extremely sensitive; injury may cause blindness!

!

Never start the engine with the valve cover  removed. There is a risk of personal injury.

!

Never use start gas or similar products as a starting aid. They may cause an explosion in the inlet manifold. Danger of personal injury.

!

Stop the engine before working on the cooling system. Marine engines: Close the sea cock / cooling water inlet valve before work on the cooling system is begun.

!

 All fuels, as well as many chemicals, are flammable. Do not allow open flames or sparks in their vicinity. Gasoline, some thinners, and hydrogen gas from batteries are extremely flammable and explosive when mixed with air in the correct proportions. No Smoking! Ensure Smoking! Ensure that the work area is well ventilated and take the necessary safety precautions before welding or  grinding work is begun. Always ensure that there are fire extinguishers close at hand in the work area.

!

Make sure that oil, fuel-soaked rags, and used fuel and oil filters are stored in a safe manner. Rags soaked in oil can spontaneously ignite under certain circumstances. Used fuel and oil filters are environmentally hazardous waste and must be handed to an approved waste management facility for destruction, as must any used lubrication oil, contaminated fuel, paint residue, solvents, degreasers and wash residue.

!

Batteries never be exposed to open flames or must electric sparks. Never smoke in the vicinity of the batteries; they generate hydrogen gas when charged, which is explosive when mixed with air. This gas is easily ignited and highly explosive. A spark, which can be caused by incorrect battery connection, is sufficient to cause a battery to explode and cause damage.

!

Never work alone heavy components, evenwhen whenremoving using lifting devices such as locking tackle lifts. When using a lifting device, two people are usually required to do the work - one to take care of the lifting device and the other to ensure that components are lifted clear and not damaged during the lifting operations.

!

The existing lugs on the engine should be used for lifting. Always check that the lifting equipment used is in good condition and has the th e

Do not touch the connections during start attempts. Sparking hazard! Do not lean over  batteries.

!

Never transpose the positive (+) and negative (-) battery posts when installing batteries. Such a transposition can result in serious damage to electrical equipment. Refer to the wiring diagram.  Always use protective goggles when charging and handling the batteries. Battery electrolyte contains sulfuric acid which is highly corrosive. Should the battery electrolyte come into contact with unprotected skin, wash it off immediately using soap and copious amounts of water. If you get battery acid in your eyes, flush at once with copious amounts of water and seek medical assistance immediately.

load capacity to lift the engine (engine weight including gearbox or extra equipment). For safe handling and to avoid damaging components fitted to the top of the engine, the engine must be lifted with a correctly adjusted lifting boom.  All chains or wires must run parallel to each other and as perpendicular to the engine as possible. If other equipment attached to the engine has altered its center of gravity, special lifting devices may be needed to obtain the correct balance for safe handling. Never  perform any work on an engine that is only suspended from the lifting equipment.

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05-1 Safety Instructions

!

The components in the electrical and fuel systems on Volvo Penta products are designed and manufactured to minimize the risk of fire and explosion. The engine must not be run in areas where there are explosive materials.

!

Exercise extreme caution when leak-detecting on the fuel system and testing the fuel injector  nozzles. Use eye protection. The jet from a fuel nozzle has very high pressure and great penetration 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 recommended by Volvo Penta. Refer to the Operator's Manual for the product in question. Use of fuels that are of a lower grade may damage the engine, the injection pump and the injectors. On a diesel engine, low grade fuel can cause the 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.

!

Never use a high-pressure washer for cleaning the engine. Pay attention to the following when using a highpressure washer on components other than the actual engine: Never direct the water jet at seals, rubber hoses or electrical components.

!

Fuel delivery pipes must not be bent or  straightened under any circumstances. Cracks may occur. Damaged pipes must be replaced.

!

When working on the engine; perform leakage and function test as necessary.

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08-2 Special Service Tools

08-2 Special Service Tools The following special tools are used when working on the engine. The tools may be ordered from AB Volvo Penta by specifying the number indicated.

 

VODIA

      5        7      6       5       8       8         3

      5

     4

     2      1

P

67

885675 Break-out cable  Adapter cable for sensor  testing.

p

8 75

p0005125

88820047 VODIA, diagnostic tool Complete tool.

88890074 Multimeter 

9998482 Measuring tool Measuring tool for control unit connector.

9998534 Break-out cable 4-pole adapter cable for sensor  testing.

Used for taking readings.

P0008793

9990014 Break-out cable Used for EMS2.

p0005128

9998699 Break-out box Used for taking readings.

88890016 Break-out cable For use with 9998699 Breakout box.

30

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08-2 Special Service Tools

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30-0 General

30-0 General Design and Function Component location Location of sensors, D9 non-classified 4

3

5

2

6

1 7

11

8 9 10

P0007164

12 13

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30-0 General

Location of sensors, D9 non-classified 1 Se Sens nsor or,, cool coolan antt leve levell 2 Se Sens nsor or,, cr crank ankca case se pre press ssur ure e 3 St Stop op bu butt tton on and and fu fuse ses s 4 Sensor, Sensor, combined combined air inlet pressure pressure and intake manifold manifold temperature temperature 5 Sensor, Sensor, combined combined oil pressur pressure e and oil temperat temperature ure (engine) (engine) 6 DC/D DC/DCC-co conv nver erte ter  r  7 Se Sens nsor or,, fuel fuel press pressur ure e 8 Se Sens nsor or,, wat water er in in fuel fuel 9 Se Sens nsor or,, coo coola lant nt te temp mper eratu ature re 10 Switch, Switch, oil level level (opti (optional) onal) 11 Engine control control unit unit (EMS2) (EMS2) 12 Sensor, Sensor, camshaft camshaft posi position tion 13 Sensor, Sensor, flywheel flywheel position position

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30-0 General

Location of sensors, D9 classified 4

2

5

3

1

6

7 12

1  2    S   3   B S   S  4  S  5  BROKEN RO   S  6  RO   S   S S V K E N KEN W T W  W E EF  S IIRR E T   T D  E S E E !   E R  P S L  E R  O O R I   E  O V T W  O   O  C   N I   E T  S  K O   3  A  R L    ,S B 2  4  P  S     E R  SM RR  S S  F O  OA U L   U T F T TA    E C  CD T EE TE  A L E S   LA D EP SH HUTDO HU R MS   D U RO MS  S TD NN TDO  R R W WN E U  U N  R UE 1  V W R   S  2  W S  3 4   O  O    SS  5  P 6  N S  S   S R WD   G L E YR E N R  G

1   S 2   2    S 2 3      S 2   4    S 2   5    S 2 6      S 2  5    6    6   .P  6  2   A 1   S TR .  S M  S . E  S  S 2   R  S . T E  O2  3     E  S R T P E  S  S . 2  1   N L R E P A . I  P P I   R M P L    O L I   M E   I   O T E O R  O  O N T L D T E O A C I  T  C . A I   E E E  6    O S E  G G L 6 T G L  G N P 1 N  O O .G  S   A D  6  E  O  U S 2 .  6  R A  S O  G 2 T W N A  C H E  0 C E     C  3  T W 6 A I  O I   X V  6 F  8  O E  O O  0     U 1  N D 7  2    8  

N A M

 8  UT    U  3   U U H S  S

2 9     2   0   1  2   1   1   2  2   1   2   S S  O 2  B  S 2   F  S 2  

2   L  2   S4   2   2    S    8 8  2 8 

8 18

11 10

9

13 14

17

15

16

P0017067

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30-0 General

Location of sensors, D9 classified 1 Se Sens nsor or,, cool coolan antt leve levell 2 Se Sens nsor or,, cr crank ankca case se pre press ssur ure e 3 Aux Aux sto stop p but butto ton n 4 Sensor, Sensor, combined combined air inlet pressure pressure and intake manifold manifold temperature temperature 5 Sensor, Sensor, combined combined oil pressur pressure e and oil temperat temperature ure (engine) (engine) 6 Power Mo Module 7 Se Sens nsor or,, fuel fuel press pressur ure e 8 Se Sens nsor or,, wat water er in in fuel fuel 9 Se Sens nsor or,, coo coola lant nt te temp mper eratu ature re 10 Switch, Switch, oil level level (opti (optional) onal) 11 Engine control control unit unit (EMS2) (EMS2) 12 SDU (Shutdown (Shutdown U Unit) nit) 13 Sensor, Sensor, camshaft camshaft posi position tion 14 Sensor, Sensor, flywheel flywheel position position 15 Sensor, Sensor, freshwater freshwater pres pressure sure 16 Sensor, Sensor, piston cooling cooling pressure pressure 17 Sensor, Sensor, seawater seawater pressure pressure 18 Sensor, Sensor, exhaust temperat temperature ure

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30-0 General

Location of sensors, D11

P0018112

 

35

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30-0 General

Location of Sensors, D11 1 Se Sens nsor or,, cr crank ankca case se pre press ssur ure e 2 Se Sens nsor or,, cool coolan antt leve levell 3 Sensor Sensor,, p pist iston on cooling cooling pressu pressure re 4 Se Sens nsor or,, fuel fuel press pressur ure e 5 Sensor Sensor,, combine combined d oil press pressure ure / oil oil tempera temperature ture 6 Se Sens nsor or,, flyw flywhe heel el pos posit itio ion n 7 Sensor, Sensor, air inlet pressure pressure / intake manifold manifold temperatu temperature re 8 Sensor, Sensor, seawater seawater pressure pressure (D11B3-A (D11B3-A MP, D11B4-A D11B4-A MP) MP) 9 Se Sens nsor or,, ca cams mshaf haftt posi positi tion on 10 Sensor, freshwater pressure (D11B3-A MP, D11B4-A MP) 11 Sensor, Sensor, coolant coolant temperat temperature ure 12 Sensor, Sensor, engine oil lev level el

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30-0 General

Location of sensors, D13

P0019225

 

37

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30-0 General

Location of Sensors, D13 1 Seawater Seawater pressure pressure sensor sensor (D13B-C/D/E (D13B-C/D/E/F/L/M /F/L/M/N, /N, D13C3-A, D13C3-A, D13C4-A D13C4-A only) 2 Fu Fuel el pre press ssur ure e sens sensor  or  3 Charge pressure pressure sensor sensor / Charge Charge air temperat temperature ure sensor  4 a Auxiliary Auxiliary stop (D13B-A (D13B-A/B/G/H /B/G/H/J/K, /J/K, D13C1-A, D13C1-A, D13C2-A D13C2-A only) only) b Emergency stop (D13B-C/D/E/F/L/M/N, D13C3-A, D13C4-A only) 5 a Exhaust temperature sensor (1) (D13B-C/D/E/F/L/M/N, D13C3-A, D13C4-A only) (2)

b Exhaust temperature alarm  (D13B-A/B/G/H/J/K, D13C1-A, D13C2-A only) 6 Level sensor sensor for water water separator separator (D13B-A/B (D13B-A/B/G/H/J /G/H/J/K, /K, D13C1-A, D13C1-A, D13C2-A D13C2-A only) only) 7 En Engi gine ne con contro troll un unit it ((EM EMS2 S2)) 8 Oil level level a and nd o oilil temp temperat erature ure sens sensor  or  9 Cr Cran ankc kcas ase e sens sensor  or  10 Oil pressure pressure sensor  sensor  11 Coolant Coolant level level monitor  monitor  12 Tachometer Tachometer sensor, sensor, flyw flywheel heel 13 Rpm sensor, sensor, camsha camshaft ft 14 Coolant Coolant temperature temperature se sensor  nsor  15 Freshwater pressure sensor (D13B-C/D/E/F/L/M/N, D13C3-A, D13C4-A only)

1. Reads exhaust temperatures. 2. Warns if the temperature rises severely, which it will if water is not supplied.

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30-0 General Location of sensors, D16

P0019215

 

39

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30-0 General

Location of Sensors, D16 1 Swit Switch ch,, cool coolant ant leve levell 2 Power Mo Module 3 Sensor Sensor,, boost boost pressu pressure re and boos boostt tempera temperature ture 4 Se Sens nsor or,, fuel fuel press pressur ure e 5 Se Sens nsor or,, coo coola lant nt te temp mper eratu ature re 6 Se Sens nsor or,, wat water er in in fuel fuel 7 Se Sens nsor or,, cr crank ankca case se pre press ssur ure e 8 Sensor Sensor,, oil oil temper temperatu ature re and and oil oil level level 9 Se Sens nsor or,, oil oil pr pres essu sure re 10 Sensor, Sensor, seawater seawater pressure pressure 11 Emergency Emergency s stop top bu button tton 12 Tachometer Tachometer sensor, sensor, flyw flywheel heel 13 Rpm sensor, sensor, camsha camshaft ft 14 Switch, Switch, piston piston cooling cooling 15 Sensor, Sensor, freshwater freshwater pres pressure sure

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30-0 General

Component description AUX stop button There are two different kinds of AUX stop buttons. When the AUX stop button is pressed the power supply to the engine control unit (EMS2) is switched off and the engine will shut down. Non-classified system The aux stop breaks a circuit from the main relay to the EMS2.

  Classified system The aux stop breaks two circuits from the power  module to the EMS2. On D13 engines a circuit will also close which indicates that the aux stop is pressed.

Starter motor 

P0007169

1

 

The starter motor is installed in the flywheel housing, on the right-hand side of the engine. The starter motor  relay is connected between battery positive and an d EMS2. When the relay is to be activated during the starting sequence EMS2 alter the potential of the output. The starter motor solenoid is engaged via the starter  relay, which is activated when the starter key is turned to position III. The starter relay (1 (1) is installed on the side of the starter motor solenoid. If there is no power module installed, a first-start relay is also included in the starter motor circuit. This is located underneath the plastic housing beside the stop button bracket. Overheating protection The starter motor circuit is automatically cut for 30 seconds to protect the starter motor against overheating. Leave the starter motor to cool for at least five minutes (if possible) before making a new start attempt.

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30-0 General

Alternator 24 V – 80 A, 12 V – 115 A The alternator is belt driven and mounted on the front of the engine, on the left.

 

Wastegate valve (D12, D13 single turbo) The engine is equipped with a turbocharger with a wastegate. The wastegate controls the amount of  exhaust gas flow that passes through the exhaust turbine. Air pressure taken from the inlet manifold is used to control the amount that the wastegate opens. The wastegate valve is controlled by the EMS2. The EMS2 uses a pulse width modulated signal to control the wastegate valve position.

Wastegate valve (D13 twin turbo) The engine is equipped with two turbochargers with a wastegate valve. The wastegate valve controls the amount of exhaust gas flow that passes through the exhaust turbine. Oil pressure is used to control the amount that the wastegate valve opens. The wastegate valve position is controlled by a solenoid that is controlled by the EMS2 The EMS2 uses a pulse width modulated signal to control the wastegate valve position.

P0010639

 

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30-0 General

Unit injector  The unit injectors are installed on the cylinder head, underneath the valve cover. The amount of fuel injected and injection duration is controlled by the control unit, via electromagnetically controlled fuel valves in the unit injectors. This means that the engine always receives the correct volume of  fuel in all operating conditions, which offers lower fuel consumption, minimal exhaust emissions etc.

 

The unit injectors are made and classified by tolerance. Each unit injector is marked with a code on the top side of the electric connection. If an injector is replaced, the new code must be programmed for the cylinder  concerned using VODIA.

Piston cooling switch (D12, D16)  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 240 kPa (35 PSI), 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 EMS2. A preset pressure limit of 150 kPa (22 PSI) determines when the monitor switches on. The monitor opens if the pressure exceeds this value.  At idle, the monitor can be closed without a fault code being set.

Sensor, piston cooling (D11) The sensor measures piston cooling pressure and is located in front of the engine. 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 proportional to the pressure that the sensor  measures.

Sensor, fuel pressure 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 sup ply voltage of +5 Volt. The sensor provides an output signal whose voltage is proportional to the pressure that the sensor measures.

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30-0 General

Sensor, coolant temperature  

D9, D12, D16

The sensor is located on the left-hand side of the cylinder head. The sensor consists of a non-linear resistor, whose resistance varies with coolant temperature. The resistance falls as the coolant temperature rises.

  D11, D13

p0004941

  D9, D12

Sensor, air inlet pressure / intake manifold temperature The air inlet pressure and intake manifold temperature are measured by a combined sensor, which is located in the inlet manifold. The sensor is supplied by a 5 Volt reference voltage from the engine control module.

D11, D13, D16

The air inlet pressure sensor  measures  measures the absolute pressure, which is the sum of the air inlet pressure and atmospheric pressure. 300 kPa (44 PSI) corresponds with a charge pressure of 200 kPa (29 PSI) when atmospheric pressure is 100 kPa (15 PSI)). The sensor provides a voltage signal which is proportional to absolute pressure. The intake manifold temperature sensor  consists  consists of a non-linear resistor, whose resistance varies with charge air temperature. The resistance falls as the temperature rises.

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Sensor, oil pressure / oil temperature, engine Oil temperature and oil pressure are measured by a combined sensor. The sensor is supplied with 5 Volt from the engine control module. The sensor is installed on the oil filter bracket and measures the pressure in the main oil gallery.

 

The oil temperature sensor  consists  consists of a non-linear  resistor, whose resistance varies with engine oil temperature. The resistance falls as the oil temperature rises. The pressure signal gives signal gives an output signal whose voltage is proportional to the pressure that the sensor  measures.

D9, D12, D16

Sensor, camshaft position The camshaft position sensor is located furthest furthe st back on the right side of the engine and is identical iden tical with the engine speed sensor. The sensor is inductive. Theofsensor a toothed wheel with seven teeth (six which reads have the same spacing) on the camshaft. The impulses from the cam position sensor provide the control unit with information about the cylinder which is next in line for  fuel injection.

Sensor, engine speed (flywheel) D11, D13

The sensor is located on top of the flywheel housing and is identical with the camshaft position sensor. The sensor is inductive. This reads the crankshaft angle and speed by means of grooves in the flywheel. The signal is sent to the control unit, which calculates the injection advance and the amount of fuel to be injected.

P0008694

External stop relay The engine is equipped with a relay that can be remotely controlled by third part equipment, e.g. a fire extinguishing system. The engine individually shuts down when the relay is energized. NOTICE! Leave the external stop connector  NOTICE! Leave unconnected if the functionality is not to be used. Fault codes presented on Vodia when external stop relay is activated: MID 128, PPID 6, FMI 11

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Engine control unit (EMS2) The control unit checks and controls the unit injectors, to ensure that the correct volume of fuel is injected into each cylinder. It also calculates and adjusts the injection advance. Regulation is mainly done with the aid of the engine speed sensors and the combined sensor for air inlet pressure / intake manifold temperature. The EMS2 system processor is located in the control unit, unit, protected from water and vibration. The processor receives continuous information about:

• Engine Speed  

• Throttle opening • Oil pressure • Oil temperature • Crankcase pressure •  Air inlet pressure / intake manifold temperature • Fuel pressure • Fuel alarm, water in fuel • Camshaft position • Coolant level / oil level • Coolant temperature • Piston cooling pressure The information provides information about current operation conditions and allows the processor to calculate the correct fuel volume, monitor engine status etc.

Sensor, crankcase pressure The sensor that is measuring the crankcase pressure is located on the valve housing. The sensor provides an output signal whose voltage is proportional to the pressure that the sensor measures. The sensor is supplied with 5 Volt from the engine control module.

Switch, lube oil level (optional) (D9, D11, D12) The switch is located on the left-hand side of the oil pan. The switch can assume two states, on/off. When the oil level is correct, the monitor is on, i.e. a current flows to the EMS2.

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Oil level/temperature sensor (D9CC, D13, D16) 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 proportional to the oil level. A 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.

 

Switch, coolant level The switch is located under the coolant expansion tank. The level monitor comprises two parts, the actual monitor and a magnetic float built into the expansion tank. The monitor senses the position of the magnetic float. When coolant level drops, the float acts on the level monitor whose resistance drops to zero whereupon a circuit either closes (old model) or opens (new model). 1

P00171 717 74

1

NOTICE! When changing from a normally open (NO) NOTICE! When switch to a normally closed (NC) switch, make sure that it is programmed in a correct manner. The EMS2 software must be upgraded. The old switch has a black label and is NO. The new switch has a blue label and is NC.

Ne New w mod model el:: B Blu lue e lab label el (NC) (NC) Old model: Black label (NO)

 

Water switch, secondary fuel filter   A switch is located underneath the secondary fuel filter  in the water trap. Its task is to discover water in the fuel system. The switch consists of two copper pins, between which resistance is measured. When the resistance falls below a limit value (which happens when water gets into the fuel), the control module receives an alarm signal.

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Power Module The Power Module is used on classified installations with a backup battery.  An electronic relay function on the Power Module regulates the power supply from the batteries onto the rest of the system. The Power Module also ensures that both batteries are connected and monitors the battery voltage.

  B1

PM

15A

 AUX stop

EMS2 B2 7A

EVC/MCC

7A

EasyLink

The Power Module has a J1708/J1587 data link to communicate with the EMS2 and EVC/MCC. The Power Module monitors that the EMS2 and EVC/MCC is active. The Power Module has auto fuses to prevent too high current from reaching the EMS2 (EMS supply), EVC/MCC (30 supply) and EasyLink (Extra supply).

P0016541

 

DC/DC converter (only D9) The DC/DC converter is used on engines with 12 V system voltage. The DC/DC converter retains sufficient power to the electrical system at crank. It also power supplies the system at normal operation.

P0016555

 

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SDU (Shutdown Unit) The shutdown unit is an independent safety system to stop the engine in case of serious malfunction. The SDU is designed to fulfill all classification societies demands on safety system for propulsion engines and generator sets. On D9 and D16 engines the SDU controls a fuel cutoff valve which activates in case of shutdown. D13 engines have a power relay that opens and cuts power  P0011559

 

to EMS2 in case of shutdown. The sensors to the SDU are type approved switches for oil pressure, gear oil pressure and coolant temperature. The switch level is designed to be activated after the EMS2 normal alarm and derate operation. The SDU can be overridden and will therefore temporarily not shut down the engine if the operator  activates this function. Over speed shut down is not affected and is always active. Overspeed pickup (unique sensor) is placed on the flywheel to measure over speeding of engine, 15% over nominal speed. When replacing the SDU it must be configured manually. The SDU only consists of hardware, no software. The SDU indicates status on its outputs. In an MCC system the SDU is connected to an MCU panel. In an EVC system the SDU is connected to an SDU panel.

SDU Control Panel

Marine Control Unit (MCU)

P0011560 P0017109

IMPORTANT!

• MCU prop engines emulates PCU (MID 187) • MCU aux engines emulates DCU (MID 144)

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SDU shutdown channels Coolant temperature switch (S1) (D9 CC, D13 CC, D16 CC)

P0017121

Coolant temperature is monitored by a temperature switch. The temperature switch’s output signal can only indicate one of two positions, on/off, just like a relay output. A preset temperature limit determines when the switch switches from one distinct position to another. The switch’s purpose is to detect if coolant temperature tempe rature becomes too high.

  Oil pressure switch, reverse gear (S2) (D9 MH, D13 MH, D16 MH) The oil pressure in the reverse gear is monitored by a pressure switch. The pressure switch’s output signal can only indicate one of two positions, on/off, just like a relay output. A preset pressure limit determines when the switch switches from one distinct position to

P0017122

another. The switch’s purpose is to detect if the oil pressure in the reverse gear becomes too low.

  Oil pressure switch, engine (S3) (D9 CC, D13 CC, D16 CC) The oil pressure in the engine is monitored by a pressure switch. The pressure switch’s output signal can only indicate one of two positions, on/off, just like a relay output. A preset pressure limit determines when the switch switches from one distinct position to another. The switch’s purpose is to detect if the oil pressure in the engine becomes too low.

P0017123

 

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Coolant pressure switch (S4) (not standard) Coolant pressure is monitored by a pressure switch. The pressure switch’s output signal can only indicate one of two positions, on/off, just like a relay output. A preset pressure limit determines when the switch switches from one distinct position to another. The switch’s purpose is to detect if the coolant pressure becomes too low.

P0017124

  Oil temperature switch (S5) (not standard)

P0017121

 

Oil temperature in the engine is monitored by a temperature switch. The temperature switch’s output signal can only indicate one of two positions, on/off,  just like a relay output. A preset temperature limit determines when the switch switches from one distinct position to another. The switch’s purpose is to detect if the oil temperature in the engine becomes too high. This channel could also be used as an extra emergency stop.

Exhaust temperature sensor (S6) (not standard) The sensor is placed in the exhaust bend after the turbocharger. Exhaust temperature sensor consists of  a Pt-200 sensor. Its resistance changes depending on the temperature (the resistance increases with rising temperature). The sensor’s purpose is to detect if the exhaust temperature is too high.

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Sensor, engine rpm The speed sensor is an inductive sensor, placed in the transmission gear casing. The sensor’s purpose is to detect overspeed.

P0016347

 

Fuel shut off valve The valve is an electrical two directional valve. The valve position is controlled by a signal from the SDU. When no signal is present, fuel feed operates normally. If as signal is received from the SDU, an electromagnet is engaged, changing the valve position, thus stopping the fuel feed and shutting down the engine. When the valve is in normal operation mode the flow in the valve is P-T and F-I. When the valve is in shut down mode the flow alters to P-I and F-T. Connections in valve body, marking:

P0017140

 

T. P.

Inle Inlett ffro rom m fue fuell ttan ank k (T (Tank) Outl Outlet et to feed feed pu pump mp (Pump)

F. I.  A.

Inle Inlett ffro rom m fue fuell ffil ilte ters rs (Filters) Outl Outlet et to un unit it Inj Injec ecto tors rs (Injectors) Cable harness (Signal from engine protection unit)

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SDU adjustments

1 = Channel On / Off jumpers P0018655

Channel set-up

Switches/sensors, engine protection system

1 Loc Locate ate the the ch channe annell on/off on/off jump jumper er pins pins (1) (1) on th the e SDU card.

The respective switch or sensor shuts down the engine at the preset values found at section  Administration,  Administrati on, page 9. 9.

2 Dis Disabl able e all all th the e S1–S6 S1–S6 channel channels s before before configuring run detection and overspeed.

= Channel disabled ON

OFF

S4. = Channel enabled

ON

Chan hannel Switc itch S1. Coolant tte emperature S2. Oil pressure, reverse gear (1) S3. Oil pressure, engine(1) S5. S6.

Coolant Pressure(2) Oil temperature, engine Exhaust tte emperature

OFF

P0018656

1. ”Run detection S2, S3” 2. ”Run detection S4”

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P0018657

Run detection configuration Special tool: 88890074 Multimeter  Other special equipment: Frequency generator  The first configuration is for S2, S3 run detection. 1

Connect terminal 1 to 24 V and terminal 2 to 0 V.

2

Switch Switch on the supply supply and make make s sure ure the green green LED (POWER) is lit on the SDU. Some alarms can be activated, ignore these.

NOTICE! Frequency NOTICE!  Frequency (Hz) = rpm x pulses/revolution / 60 These values are found at section  Administration,  Administratio n, page 9. 9. 6

If the green LED (4) is not lit: Turn “A” counterclockwise (–), until the green LED is lit. The run detection limit is now configured. If the green LED is lit: Turn lit: Turn “A” slightly clockwise (+) to switch off the LED. Then turn “A” counterclockwise (–) until the green LED is lit. The run detection limit is now configured.

3

Connec Connectt a sinuso sinusoida idall freque frequency ncy generat generator or (G) (G) to to the 65, 66 inputs.

4

Connec Connectt 88 88890 890074 074 Mult Multime imeter ter in paral parallel lel with with th the e frequency generator to measure the frequency.

7

Ramp Ramp th the e fr frequ equenc ency y fr from om 0 Hz tto o the the ru run n de detec tectio tion n level to make sure that correct limit is configured.

5

Set the fre frequen quency cy gene generato ratorr to the run detecti detection on frequency.

8

Make Make th the e sa same me p proc rocedu edure re ffor or the the S4 S4 run run de detec tectio tion n (configure “B”). The S4 LED (3) color is yellow.

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P0018658

If the red LED is lit: Keep lit: Keep the shutdown reset button (R) pushed and turn "C" slightly clockwise to switch off the LED. Release the shutdown shutd own reset button. Turn "C" counter-clockwise until the red LED is lit.

Overspeed configuration Special tool: 88890074 Multimeter  Other special equipment: Frequency generator 

1

Connect Con66 nect the sin sinuso usoida idall freque frequency ncy gen genera erator tor tto o the the 65, inputs.

5

Set shutdown the fre frequen quency cy g gene enerato rator(R). r to 0 Hz and then push push the reset button

2

Connect Connect 8889007 88890074 4 Multim Multimeter eter in paral parallel lel with with the frequency generator (G) to measure the frequency.

6

Ramp Ramp th the e freque frequency ncy fro from m 0 Hz Hz to the oversp overspeed eed limit to make sure that correct limit is configured.

7

If tthe he S6 S6 ch chan anne nell is u use sed, d, proc procee eed d wi with th the the exhaust temperature configuration.

8

Enable Enable the channe channels ls S1– S1–S6 S6 accordi according ng to the engine specification (refer to section “Channel set-up”). Fit the SDU cover.

3

4

Set the fre freque quency ncy generat generator or to to the the overspe overspeed ed frequency seen in the table on the next page. If the red LED (2) is not lit: Turn lit:  Turn “C” counterclockwise until the red LED is lit.

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P0018659

Exhaust temperature configuration

Temperature

PT200 re resistance

500 °C / 932 °F

562 Ω

550 °C / 1022 °F

595 Ω

1 Calibr Calibrate ate a v varia ariable ble resi resisto storr to a shutdo shutdown wn temperature value according to the table.

600 °C / 1112 °F

628 Ω

650 °C / 1202 °F

659 Ω

2 Connec Connectt the c conf onfigu igured red resi resisto storr to the the S6, S6, 2 inputs.

700 °C / 1292 °F

690 Ω

Factory default setting for S6 is 650°C (~ 659 Ω) shutdown limit.

3 Locate Locate th the e vari variabl able e resisto resistorr “D” and cali calibrat brate e it until the S6 LED (5) is lit. – Turn counterclockwise to increase the shutdown limit. – Turn clockwise to decrease the limit. 4 Reset Reset with with th the e shutdow shutdown n reset reset button button (R). (R). Calibrate once more and then reset. 5 Enable Enable the the ch channe annels ls S1–S S1–S6 6 accordi according ng to the the engine specification. Fit the SDU cover.

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Design and Function G

System Description EMS2

A

H

EMS2* is a system for electronic diesel engine control. contr ol. The system has been developed by Volvo Penta and includes fuel control and diagnostic function.

B

I

* EMS= ”Electronic Management System”.

C

ECU

D E F

J

Control unit

K

The EMS system processor is located in the control unit, protected from water and vibration.

L

The processor receives continuous information about:

• Engine speed P0007162

O

N

M

Engine Control Unit (ECU)

• Oil pressure

 A

Engine speed

• Oil temperature

B

Thro Thrott ttle le op open enin ing g

• Crankcase pressure

C

Oil Oil pressu pressure/ re/-te -tempe mperat rature ure

D

Air iinlet nlet pressure pressure / intake intake manifold manifold tempe temperatur rature e

E

Cr Cran ankc kcas ase e pres pressu sure re

• • Fuel pressure

F

Co Cool olan antt temp temper erat atur ure e

• Fuel alarm, ”water in fuel”

G

Diag iagno nos sti tics cs

• Camshaft position

H

Ca Cams msha haft ft pos posit itio ion n

I

Fuel Fuel al alar arm, m, wa wate terr iin n ffue uell

J

Fuel pressure

K

Co Cool olan antt le leve vel/ l/oi oill le leve vell

L

Pist Piston on cool coolin ing gp pre ress ssur ure e

M Chec Checking king the waste wastegate gate contr control ol (D12)

 

• Throttle opening

N

Fuel volume

O

Inje Inject ctio ion n ad adva vanc nce e

 Air inlet pressure / intake manifold temperature

• Coolant level/oil level • Piston cooling pressure The information provides information about current operation conditions and allows the processor to calculate the correct fuel volume, monitor engine status etc.

58

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Fuel control The amount of fuel injected into the engine and the injection advance are fully electronically controlled, via fuel valves and the unit injectors, once the control unit has analyzed the engine’s fuel requirements. 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 monitors the unit injectors to ensure that the correct volume of fuel is injected into each cylinder, and it calculates and adjusts the injection advance. Regulation is mainly done with the aid of the engine speed sensors and the combined sensor for air inlet pressure / intake manifold temperature. The control unit controls the unit injectors via a signal to the electromagnetically operated fuel valve in each injector, which can be opened and closed. When the fuel valve is open, fuel flows through the holes in the unit injectors and out through the fuel duct. Fuel is not injected into the cylinders in this phase. When the fuel valve is closed, pressure is built up by the mechanically driven pump piston in the unit injector. When enough pressure has been built up, fuel is injected into the cylinder via the nozzle part of the unit injector. The fuel valve is re-opened and pressure in the unit injector falls at the same time as fuel injection to the cylinder ceases. The control unit receives signals from various sensors on the engine, which allow it to decide when the fuel valve should be opened and closed.

Calculation of fuel quantity The quantity of fuel to be injected into the cylinder is calculated by the control unit. The calculation gives the time when the fuel valve is closed (fuel is injected into the cylinder when the fuel valve is closed). The parameters which govern the amount of fuel injected are:

• Demanded engine speed • Engine protection functions • Intake manifold temperature •  Air inlet pressure Normal start Both the camshaft sensor and flywheel sensor function normally. The engine is cranked until engine control unit discovers that cylinder 1 isthe next in line for  injection. Fuel is injected and the engine starts.

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Starting without the camshaft sensor  If the engine control unit discovers that the camshaft signal is not available, the engine control unit will still attempt to start the engine. When the engine control unit detects a break in the pulse train from the flywheel sensor, one of the cylinders is in the position for  injection, but the engine control unit does not know which one. The engine control unit guesses which cylinder is next in line, and injects fuel at the same time as it monitors engine speed to see if it increases. If engine speed does not increase, the guess was wrong and the engine control unit u nit tries again. It will take a bit longer time to start the engine, en gine, but it will start with no problems apart from setting a fault code.

Starting without the flywheel sensor  If the engine control unit discovers that the flywheel signal is not available, the engine control unit will still attempt to start the engine. Injection will be monitored using information from the camshaft sensor. Injection will not be as exact as normal, and the engine will have reduced power. If the engine starts, idling speed will be unstable. The engine control unit will not be able to do any cylinder  balancing.

Cylinder balancing During idling, the control unit can provide the cylinders with different amounts of fuel. This is to give the engine more even idling. At higher engine speeds, all cylinders receive the same amount of fuel.

Diagnostic Function The EMS system has a built-in diagnostic function which can discover any faults in the engine and sensors. The function of the diagnostic function is to discover  and localize any function faults in the EMS system, to protect the engine and guarantee continued operation if a serious function fault should occur.

Idling adjustment (low idle) Idling speed can be adjusted to a value between 500– 750 rpm.

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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 electronics. IMPORTANT! The system must be switched off and the system current disconnected when any of the connectors on the engine control unit is connected or disconnected. • Never Never disc disconn onnect ect the current current wit with h the the main main switches when an engine is running. •

Never Never undo undo a batter battery y ca cable ble when when the the engin engine e is running.

•

Turn Turn the the main main swit switche ches s off off or discon disconnec nectt the the battery cables during quick charging of the batteries. NOTICE! During normal trickle charging, it is not NOTICE! During necessary to turn the main switches off.

•

Only Only batter batteries ies may be be use used d for start start he help. lp. A hel help p start device can produce a very high voltage and damage the control unit and other electronics.

•

If damag damage e is discov discovere ered d in a cab cable le harn harness ess the two 36-pin connectors for the enginecontrol unit and the 8-pin connector between the engine and the EVC system must be disconnected.

•

If a connect connector or iis s disco disconnec nnected ted fro from m a sens sensor, or, b be e very careful to avoid allowing the contact pins to come into contact with oil, water or dirt.

Electrical Welding IMPORTANT! Undo all connectors from the engine control unit before you start electric welding. IMPORTANT! Cut the engine current before the control unit connector is disconnected. Cut the current with the main switches. Then disconnect all connections to the alternator. Undo the connector from the engine control unit and from the power supply unit. Please refer to more detailed instructions in the ”Workshop manual group 21–26, ”Control unit, changing”.

 

Connect the welder earth clamp to the component to be welded, or as close as possible to the weld site. The clamp must never be connected to the engine or in such a way that current can pass through a bearing. IMPORTANT!  After welding is completed, the disconnected components, such as alternator cables and battery cables must be connected in the correct order.

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Fault tracing of cables and connectors Special Tools: 9812519, 9998482.

Contact problems

Check all connectors visually

Intermittent contact or temporary recurring faults can be difficult to fault trace, and are frequently caused by oxidation, vibration or poorly terminated cables.

Check the following: •

Look Look for for oxi oxidati dation, on, which which can can impa impair ir cont contact act in connectors.

Wear can also cause faults. For this reason, avoid disconnecting a connector unless it is necessary.

•

Check Check that that termin terminals als are undamag undamaged, ed, that that they they are correctly inserted into their connectors, and that the cable is correctly terminated in the terminal.

Other contact problems can be caused by damage to pins, sockets and connectors etc.

•

•

Check Check that that there there is goo good d mecha mechanic nical al c cont ontact act in 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 gauge 9998482. Carefu Carefully lly inser insertt gauge gauge 99 999848 98482 2 into into the multip multipin in 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 multi-connector” Check the secondary locking in the connector.

Shake cables and pull connectors during measurement, to find where the cable is damaged. Contact resistance and oxidation Resistance in connectors, cables and junctions should be close to 0 Ω. A certain amount am ount 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 malfunctions 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 cable harnesses har nesses which are relevant to the function. Start off with the most probable cable harness in the circuit. Check the following:

•

If poss possibl ible, e, shak shake e th the e cable cables s and and pull pull tthe he connectors during measurement to discover  whether the cable harness is damaged.

•

Check Check that that the cables cables are not damaged damaged.. Avoid Avoid clamping cables in tight bends close to the connector.

•

Check Check the the func functio tion n of the second secondary ary lockin locking. g.

•

Discon Disconnect nect the rel releva evant nt c conne onnecto ctorr at e each ach end of the cable harness.

•

Us Use e multi multime mete terr 981 98125 2519 19 tto o measu measure re tthe he resistance between the ends of the cable. Nominal value close value close to 0 Ω.

•

If poss possibl ible, e, s shak hake e th the e cable cables s an and d pu pullll tthe he connectors during measurement to discover  whether the cable harness is damaged.

•

Check Check tthe he next next cab cable le h harn arness ess in the the wiri wiring ng schedule if no fault has been found.

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Connection of 9998699 Break-out box to EMS2 Special Tools: 9990014, 9998699. 1

Dismount the engine control unit by loosen the 4 bolts.

2

Loosen the clamps to the connectors.

3

Remove engine connector A or B, depending on what to measure, by lifting the yellow locking handle.

P0008528

 

P0008529

 

P0008530

 

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     9      9      6      8      9      9      9

Connect the engine control unit connector to the brakeout cable 9990014 (1 (1). Connect the brakeout cable 9990014 to the engine control unit (2).  All pins from the engine control unit is accessible accessible in the measurebox 9998699.

   7

  6   1   4

   5   4   3   2   1

  1   1   0   1

  9   8

  3   1   2   1

   7   1   6   1

   5   1

  3   2

  2   3

  0   3

  8   3

  4   4

  6    5    5    5

  4    5   3    5

  2    5   1    5

  0    5

  9   4   8   4

   7   4   6   4

   5   4

  3   4

  2   4   1   4

  0   4   9   3

   7   3   6   3

   5   3   4   3

  3   3

  1   3

  9   2

  8   2    7   2

  6   2    5   2

  4   2

  2   2

  1   2   0   2

  9   1   8   1

  2   6   1   6

  0   6   9    5

  8    5    7    5

P0008531

 

Fault tracing of the starter motor and windings Special Tools: Multimeter 9812519. General If battery voltage falls below 24.7 V (measured at the battery), 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. Checking the power supply 1

Check that the battery voltage is at least 24.7 V unloaded, by measuring the battery terminals with multimeter 9812519.

2

Turn on the main switch.

3

Check that the voltage between positions 30 and 31 on the starter motor is the same as the battery voltage.

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Checking the charging system

Fault tracing the charging system

Special Tools: 9812519.

Battery

Generally about alternators:

1 Check Check th that at all all con connect nectors ors a att the battery battery is is correctly assembled.

The voltage output from an alternator must be limited to prevent the elecrolyte in the battery to evaporate. The alternator output is regulated (limited) by the voltage regulator in the alternator. The maximum current that the alternator can deliver at regulated voltage output depends on the alternator revolution. To make the alternator charging more efficient a sense cable between the alternator and the battery+ can be added to compensate if there is a voltage drop in the cable between the alternator and the battery+. When the engine is started an excitation current is needed to “wake up” the alternator. NOTICE! It NOTICE!  It is the consumers (batteries included) which decides the output current from the alternator.

Measurements

2 Check Check the c cond onditi itions ons of the the cab cables les tto o the ba batte ttery. ry. 3 Check Check tthe he wate waterr level level iin n the bat battery tery.. 4 Check, if pos possible sible,, the specific specific gra gravity vity of all all cells. cells. when no charge 1 Check Check tthe he alte alterna rnator tor belt tensio tension. n. 2 Check Check th that at all all con connect nectors ors a att the al altern ternato atorr and at the battery is correctly assembled. 3 Check Check th the e con condit dition ion of of all cabl cables es in tthe he chargi charging ng system. 4 Check Check th the e brushe brushes s len length gth and and co condi nditio tion. n. 5 Change, Change, if p poss ossibl ible, e, tthe he regul regulator ator..

1 Engine of off.

when undercharge

2 Use multim multimete eterr 981251 9812519 9 to do do a volt voltage age measurement over the battery. The nominal voltage over a full loaded battery is approx. 12.6V or 25.2V.

1 Check Check tthe he alte alterna rnator tor bel beltt te tensi nsion. on.

3 En Engi gine ne on. on. R Run un at 150 1500 0 rp rpm. m. 4 Use multim multimete eterr 981251 9812519 9 to do do a volt voltage age measurement over the battery. The nominal charging voltage over the battery should be approx. 13.6–14.4 V or 27.8–28.6 V (if the sense cable is connected).

2 Check Check th that at all all con connect nectors ors a att the al altern ternato atorr and at the battery is correctly assembled. 3 Check Check th the e con condit dition ion of of all cabl cables es in tthe he chargi charging ng system. 4 Check Check th the e brushe brushes s len length gth and and co condi nditio tion. n. 5 Change, Change, if p poss ossibl ible, e, tthe he regul regulator ator.. when overcharge 1 Change, Change, if p poss ossibl ible, e, tthe he regul regulator ator..

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Checking alternator brushes Alternator brush removal Valid for alternator 3587218 and 3840182. 1

Pull out the black plastic lid.

2

Use a screwdriver to snap of the plastic lid over  the brush holders.

3

Disassemble the two torx screws that holds the two brush holders.

P0008398

 

P0008399

 

P0008405

 

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Pull out the brushes.

5

If the brush is worn beyond the wear limit line, 5 mm (0.2"), it must be replaced.

  8

P0008406

 

P0008407

  Alternator brush installation 1

P0008408

 

Take care to that the brushes are placed according to the illustration when installing.

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Alternator faulttracing Valid for alternator 20409228. NOTICE! Cut  Cut the current with the main switch. • NOTICE!

• Remove all connectors on the alternator. B+, B–, etc.

• Remove the plastic cover over the diods. The plastic cover is fixed with two nuts on B1+, B2+, and a pozidrive screw. • Loosen 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 the multimeter 9812519 to diode measurement. • Connect the probes between the brushes. Check that there is no short circuit. the probe points and check that there is no • Switch short circuit. NOTICE! If  If a regulator fault is suspected install a • NOTICE! new regulator and test run the charge system.

  Checking the rotor 

• Set the multimeter 9812519 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 

• Set the multimeter 9812519 to diode measurement. • 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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Energizing sequence 1

When the main switch is closed, the engine control unit pin A8 (main relay hold) gets battery potential. Main relay is not activated. The PCU and HCU are energized (via the engine connector pin 4).

2

When the starter key is turned to position I (terminal 15a on the starter switch is connected to 30), thesignal enginefrom control pin A58 anpin activation theunit PCU via pinreceives 5 in the engine connector. Pin A8 alter its potential to approx. 0.8 V and the main relay activates. When the ignition is switched, the EVC equipment such as the control panels and instruments are activated. All relays connected to the starter switch and start / stop panels are activated to supply current to equipment which does not belong to the EVC.

Changing the engine control unit 1 NOTICE!  Cut the current with the main switch. NOTICE! Cut IMPORTANT! The system must be disconnected from system voltage when the engine control unit connectors are disconnected or connected. 2 Remove Remove th the e two co conne nnecto ctors rs fro from m the en engine gine c cont ontrol rol unit. Turn the locking arm down at the same time as the connector is pulled outwards. 3 If the new new en engin gine e cont control rol unit unit has has rec recent ently ly been been programmed: Start the engine and check if there are any faults. P0008530

 

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Changing control unit Programming the control unit IMPORTANT! The chassis number or engine serial number must be available to allow the software to be downloaded. Action: 1 Log in to Volvo Penta Partner Networks web Networks web site, http://www.vppn.com 2 Cho Choose ose ”Vo ”Vodia dia”” in the leftleft-han hand d menu. menu. 3 Cho Choose ose ”ECU ”ECU Progr Programmi amming” ng” in tthe he left-h left-hand and menu. menu. 4 Follo Follow w the instru instructions ctions under under ”Download ”Download software”. software”. Choose Choose the control control units to be re-pr re-programme ogrammed d and click the ”Download” button. The software for the selected control units is now downloaded to the PDA (Personal Digital Assistant). 5 Take a lo look ok under ”S ”Setting ettings”, s”, ”Software ”Software informati information” on” in Vodia Vodia to check that that the software software has b been een downloaded. 6 Con Connec nectt the V Vodi odia a to the engi engine ne to be prog programm rammed. ed. 7 Start wi with th the engine engine control control unit. Select Select ”Engine ”Engine with with mounting mounting and equipment” equipment” in tthe he Vodia menu. menu. Select ”MID 128 Control unit, programming”. Vodia will guide you through the entire programming process. 8 The next con control trol unit is the the vehicle control control unit, unit, PCU (Powertrain (Powertrain Control Control Unit). Unit). Selec Selectt ”Electrical ”Electrical system system and instruments” in the Vodia menu. Select ”MID 187 Control unit, programming”. Vodia will guide you through the entire programming process. 9 The next co control ntrol uni unitt to be programm programmed ed is the HCU (helm (helm station control control unit). unit). Selec Selectt ”Electrical ”Electrical system system and instruments” in the Vodia menu. Select ”MID 164 Control unit, programming”. Vodia will guide you through the entire programming process. NOTICE! All helm station control units on the same drive line should be programmed in one sequence. NOTICE! All NOTICE! Auto-configuration NOTICE!  Auto-configuration must be done when programming is finished. 10 Programming must be reported back to Volvo within 28 days. Log in to Volvo Penta Partner Networks web Networks web site, http://www.vppn.com 11 Choose ”Vodia” ”Vodia” in the left-hand left-hand menu. menu. 12 Choose ” Report software” software” in the left-hand left-hand menu. 13 Follow the instructions for ”Report software/parameter”. Click ”Report software/parameter”.

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Programming an empty control unit When an ”empty” engine control unit is installed, where no software is programmed, the control unit must be programmed. If the new control unit is to replace an existing control unit, the control units must have the same part number. 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 “Programming the Control Unit”. If the part numbers are not the same, do as follows: 1 Have Have both both part part n numbe umbers rs availa available ble.. 2 Log in to Volvo Penta Partner Networks web Networks web site, http://www.vppn.com 3 Choose Choose ”Vo ”Vodia dia”” in the the left left-ha -hand nd me menu. nu. 4 Choose ”Conversi ”Conversion on kit” in the left left-hand -hand menu. A new new page, ”Conversion ”Conversion ki kitt / Accessory Accessory kit”, opens opens up. 5 Click the text text ”Available ”Available conversion conversions s kits” which which is shown in bold bold face. Follow Follow the instruction instructions s describe described d in the window. 6 Return to the ”Conversi ”Conversion on kit / Access Accessory ory kit” page and and follow the instruct instructions ions to order a new ”Conversi ”Conversion on kit”. 7 Volvo Penta’s Penta’s computer computer system system is now now updated. updated. This may may take a minute minute or so befor before e a confirmation confirmation is s sent ent back. 8 Programming Programming of the the control u unit nit can now be done, please please refer refer to “Programming “Programming the the Contro Controll Unit”.

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Function fault Fault code information •

MID (“Message Indication Description”): MID (“Message The MID consists of a number which designates the control unit that sent the fault code message. (e.g. the engine control unit).

•

SID (“Subsystem Indication Description”): SID (“Subsystem The SID consists of a number that designates a component to which the fault code relates (tachometer, for example).

•

PID (“Parameter PID  (“Parameter Indication Description”):

•

PSID (“Proprietary PSID  (“Proprietary SID”)

The PID consists of a number that designates a parameter (value) to which the fault code relates (oil pressure, for example). •

PPID (“Proprietary PID”): PPID (“Proprietary The same as the PID, but this t his is a Volvo-specific parameter.

The same as the SID, but this is a Volvo-specific component. •

FMI (“Failure Mode Identifier”): FMI (“Failure FMI indicates the type of fault (please refer to the FMI table below).

FMI table – SAE-standard FMI

Display text

SAE text

0

”Value too high”

Data valid but above normal operational range.

1

”Value too high”

Data valid but below operational range.

2

”Faulty data”

Data erratic, intermittent or incorrect

3

”Electrical fault”

Voltage above normal or shorted high

4 5

”Electrical fault” ”Electrical fault”

Voltage below normal or shorted to lower voltage 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 electric rical faul ultt”

Abnorm rma al frequenc ency, 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.

Volvo-specific for injectors (MID 128, SID 1-6) FMI

Help

2

Short circuit to battery voltage, unit injector high voltage side.

3

Short circuit to battery voltage, unit injector low voltage side.

4

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

5

Open circuit in unit injector circuit.

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NOTICE! The following must be done before fault tracing continues, to avoid changing functional sensors: NOTICE! The •

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 ”Fault Tracing the Cables and Connectors”. eng ine is stopped. Start the engine to check wheth whether  er  NOTICE! Some fault codes become inactive when the engine NOTICE! Some the fault code is still inactive with the engine running.

•

After an action with the connector  Put connector* back. Check if the fault code becomes inactive. If the fault remains, measure the cables and the sensors to check them, as instructed. NOTICE! * No grease in the connector. NOTICE! *

Problems in identifying the engine control unit (MID 128) In normal cases, VODIA identifies the engine control unit (MID 128) and the PCU (MID 187) automatically when the choice of engine installation is done.

Stop The system can not be shut down although the starter key is turned to position 0. This can be caused by a short circuit in the cables between the HCU and the key switch, by b y a short circuit

The HCU must be in service mode to allow it to be identified.

in the key switch or a fault in the stop/start panel.

If VODIA is not able to identify the engine control unit (MID 128), this will not be visible under ”Vehicle information”.

The starter motor is activated with the ignition on.

NOTICE! If the engine control unit has not been NOTICE! If identified, it can not be programmed. One reason why identification can not be done is that the PCU contains the wrong engine software or that the J1708A and J1708B data buses between the engine control unit and the PCU are short circuited to each other. In this case, Vodia can not identify a control unit.

Shut the system off with the AUX stop button.

If the starter motor is activated as soon as the switch is turned, the diode in the key switch cable harness might be short circuited. Fault trace the diode in accordance with the ”Checking the key switch diode” section.

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30-2 Fault Tracing Fault Codes MID 128, PID 20, Extended Range Engine Coolant Pressure MID 128: Engine control unit FMI 1 – Data valid but below operational range Fault code explanation: Fault indication:

Coolant pressure too low •

Warnin Warning g is disp display layed ed in the tacho tachomet meter/ er/dis displa play. y.

•

A red lamp lamp flas flashes hes iin n the alarm alarm disp display lay + a audi udible ble w warn arning ing..

Symptom:

Engine performance is reduced.

Preconditions:

Coolant pressure too low

Conditions for fault code:

Coolant pressure lower than the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Suitable action:

1 Check the coolant coolant level and th the e qual quality ity of of the coolant. coolant. 2 Chec Check k th that at no no leaka leakage ge o occ ccur urs. s. 3 Check Check the the cool coolant ant circul circulati ation on p pump ump.. 4 Check the sensor sensor by control control measuring measuring th the e coo coolant lant pressur pressure. e.

FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Preconditions:

 Abnormally high voltage or short circuit to higher voltage has been detected.

Conditions for fault code: Possible reason:

Voltage on engine control unit pin B20 exceeds 4.95 volts. • Open Open circu circuit it in in th the e senso sensorr ne negati gative ve c cable able..

Suitable action:

•

Short circuit circuit bet between ween sensor sensor signal cable and 5 V su supply pply or battery battery voltage to coolant pressure sensor.

•

Faulty se sensor 

1 Check the cable cable harness between between the sensor and th the e EMS 2. 2 Check contact contact pressure pressure in so socket cket 18 in engine connec connector tor B B.. 3 Chec Check k th the e sens sensor or..

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FMI 5 – Current below normal or open circuit Faulty sensor/Fault in sensor circuit

Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Current below normal or open circuit.

Conditions for fault code:

Voltage on engine control unit pin B20 lower than 0.07 volts.

Possible reason:

•

Open circui circuitt in the sensor sensor 5 V sup supply ply cable. cable.

•

Open Open circ circui uitt in sen senso sorr si sign gnal al c cab able le..

•

Short circuit circuit bet between ween sensor signal cable and b battery attery negati negative ve to to coolant pressure sensor.

•

Faulty sensor.

1 Check the cable cable harness harness between the s sensor ensor and tthe he EM EMS S 2.

Suitable action:

2 Check contact contact pressure pressure in so socket cket 18 in engine connec connector tor B B.. 3 Chec Check k th the e se sens nsor or..  

Circuit description

  20 GN/SB (+)17 R SB (-)18 b EMS 2

2

a

The sensor is of active type, i.e. it must be supplied with operating voltage. Pin 17 on engine control unit (EMS2) connector B supplies operating power of +5 volts to sensor pin 1. Sensor pin 4 is connected to battery negative via EMS2 pin 18. The coolant pressure sensor output signal – sensor pin 2 to EMS2 pin 20 – is a voltage signal proportional to coolant pressure. The output signal is linear within sensor working range.

1 4

P0007184

a

Cool Coola ant P Pre res ssu sure re

b

Connector B (Gray)

 

Measurements Checking supply cable, coolant pressure sensor, page 155  Checking negative cable, coolant pressure sensor, page 155  Checking signal cable, coolant pressure sensor, page 156  Checking the coolant pressure sensor, page 156 

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MID 128, PID 94 Fuel Delivery Pressure MID 128: Engine control unit FMI 1 – Data valid but below operational range Fault code explanation: Fault indication:

Fuel pressure too low. •

Warnin Warning g is disp display layed ed in the tacho tachomet meter/ er/dis displa play. y.

•

A red lamp lamp flash flashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

None

Preconditions:

Fuel pressure is too low. Fuel pressure depends on engine revolution speed.

Conditions for fault code:

Fuel pressure lower than the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Suitable action:

1 Chec Check k fu fuel el leve level. l. 2 Open Open the fuel fuel taps taps and chec check k tha thatt no le leakag akage e occ occurs urs.. 3 Check the fuel fuel hoses to ensure ensure that none have have been crushed or kink kinked. ed. 4 Change the fuel fuel filters filters (primary (primary and secondary secondary fi filter). lter). 5 Check Check the the sensor sensor by chec checkin king g the ffuel uel p press ressure ure.. 6 Check Check the overf overflow low valv valve e and cha change nge it iiff necessa necessary. ry. 7 Chec Check k tthe he fe feed ed pu pump mp..

FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Preconditions:

 Abnormally high voltage or short circuit to higher voltage has been detected.

Conditions for fault code:

Voltage on engine control unit pin B16 exceeds 4.95 volts.

Possible reason:

Suitable action:

•

Short circuit circuit bet between ween the the sensor sensor signal cable and the the sensor sensor 5 V su supply pply

•

cable or battery voltage. Open Open circu circuit it in in th the e senso sensorr ne negati gative ve c cable able..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Check contact contact pressure pressure in so socket cket 18 in engine connec connector tor B B.. 3 Chec Check k se sens nsor or..

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FMI 5 – Current below normal or open circuit Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Current below normal or open circuit.

Conditions for fault code:

Voltage on engine control unit pin 16 lower than 0.07 volts.

Possible reason:

Suitable action:

•

Open Open cir circu cuit it in 5 V supp supply ly cabl cable. e.

•

Open Open cir circu cuit it in signa signall cab cable le..

•

Short circuit circuit betw between een the the sen sensor sor signal signal cable cable and tthe he sen sensor sor n negativ egative e cable.

•

Faulty sensor.

1 Check cables and connector connectors s betw between een the sensor and en engine gine control control unit. 2 Check contact contact pressure pressure in socket sockets s 16 and and 17 iin n engine engine connector connector B B.. 3 Chec Check k th the e se sens nsor or..

FMI 7 – Mechanical system not responding properly Fault code explanation: Fault indication:

Fuel pressure too low. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Fuel pressure is too low. Fuel pressure depends on engine revolution speed.

Conditions for fault code:

Fuel pressure lower than the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Suitable action:

1 Chec Check k fu fuel el leve level. l. 2 Open the the fuel fuel taps taps and chec check k tha thatt no lea leakag kage e occ occurs urs.. 3 Check the the fuel hoses to ensure ensure that none have have been crushe crushed d or ki kinked. nked. 4 Change the fuel filters (primar (primary y and secondary secondary filter). filter). 5 Check Check the the sensor sensor by chec checkin king g the fu fuel el press pressure ure.. 6 Check Check the overf overflow low valve valve an and d chan change ge it if ne neces cessar sary. y. 7 Chec Check k tthe he fe feed ed pu pump mp..

 

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a

Circuit description The fuel pressure sensor is of active type, i.e. it must be supplied with operating power. Engine control unit connector B, pin 17, supplies sensor pin 1 with +5 volts. Sensor pin 4 is connected to the battery negative terminal via engine control unit pin 18. The pressure sensor output signal – sensor pin 2 to control unit pin 16 – is a voltage signal proportional to fuel pressure measured by the sensor. The output signal is linear within sensor working range.

GN / BL P0007189

a

Connector B Color: GrAy

  V

Component specification Working range Power supply

0–700 kPa (0–7 bar) 5.00 ± 0.25 VDC

Nominal output voltage at 25 °C (77 °F) and supply voltage 5.00 VDC: 0.5 VDC at 0 kPa (0 bar) 4.5 VDC at 700 kPa (7 bar) kPa

P0007192

V kPa

NOTICE! At NOTICE!  At normal atmospheric pressure

Output voltage Fuel pressure

 

Measurements Checking supply cable, fuel pressure sensor, page 157  Checking negative cable, fuel pressure sensor, page 157  Checking signal cable, fuel pressure sensor, page 158  Checking the fuel pressure sensor, page 158 

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MID 128, PID 97 Water in fuel indicator  MID 128: Engine control unit FMI 0 – Data valid but above normal operational range Fault code explanation: Fault indication:

Water in Fuel. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

Water-i Water-in-f n-fuel uel warn warning ing fflas lashes hes iin n the alar alarm m pan panel. el.

Symptom:

None

Preconditions:

Water in Fuel

Conditions for fault code:

Water in the fuel trap has been detected.

Possible reason:

Suitable action:

•

Wate Waterr iin n ffue uell ttra rap. p.

•

Short circuit circuit betw between een the the yel yellow low cable cable of th the e water water in fuel switc switch h and battery negative.

1 Empty Empty the water water in in the the fuel trap trap.. 2 Check Check the the cables cables to to the wat water er in fuel fuel swit switch. ch. 3 Chec Check k th the e water water in in fuel fuel swi switc tch. h.

FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Faulty sensor/Faulty switch circuit.

Conditions for fault code:

 Abnormally high voltage or short circuit to higher voltage has been detected.

Possible reason:

Short circuit between the signal cable and the supply cable to the water in fuel switch.

Suitable action:

1 Check the cable cable harness harness b between etween water in fuel fuel switch switch and EMS 2.

P0007193

 

Faulty sensor/Faulty switch circuit

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D9, D12

Circuit description

a

 A water-in-fuel monitor is located in the water  separator beneath the fuel filter. The monitor senses the resistance between two copper pins. The copper  pins are in contact with the fuel. f uel. When there is no water  in the fuel the resistance between the pins is very high. If any water is present in the fuel, the resistance falls.  At a threshold resistance (water detected) the monitor  output signal (yellow cable) to engine control unit pin 8 is reduced to zero by a transistor. Engine control unit pins 57 and 60 supply the 3-pin monitor with battery voltage. The monitor is connected to the battery negative terminal via engine control unit pin 10.

SB Y

R/BL

B A C

R/BL (+) 57 R/BL (+) 60 (-) 10 SB 8 EMS2

Y

P0007194

a

Connector B Color: GrAy

  D11, D13

D9 CC

a R SB Y

B AC

a

SB

Y

Y SB R

C AB

Y

R /BL

SB 10

8

SB

Y

EMS2

R /BL 4(+) R /BL

10

R /BL 5(+)

8

b

P0007195

SB Y

(D13)

(D11)

 A

2

B C

3

EMS2 a

Connector B Color: GrAy

b

Power Module

P0008540

a

Connector B

Measurements Checking supply cable, water switch, fuel  filter, page 160  Checking negative cable, water switch, fuel  filter, page 161 Checking signal cable, water switch, fuel  filter, page 161 Checking the water in fuel switch, fuel  filter, page 162 

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MID 128, SID 211 Sensor Supply Voltage #2 (+5 V DC) MID 128: Engine control unit FMI 3 – Voltage above normal or short circuit to higher voltage Fault code explanation:

Faulty sensor circuit

Fault indication:

Yellow alarm status

Fault stored in memory

Yes

Symptom:

None

Conditions for fault code:

Voltage on pin B17 on engíne ECU is to high

Possible reason:

Suitable action:

•

B17 short short circui circuited ted to bat battery tery voltag voltage e

•

Faulty se sensor 

1 Check the cables cables between between the sensor and tthe he eng engine ine E ECU CU 2 Chec Check k tthe he sen enso sor  r 

FMI 4 – Voltage below normal or short circuit to lower voltage Fault code explanation:

Fault in circuit.

Fault indication:

Yellow alarm status

Fault stored in memory

Yes

Symptom:

None

Possible reason:

Suitable action:

•

B17 short short circ circuit uited ed to battery battery negati negative ve

•

Faulty se sensor 

1 Check all cables cables a and nd connectors connectors between between the s sensor ensor and the engine ECU 2 Chec Check k tthe he sen enso sor  r 

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MID 128, SID 253 Calibration memory EEPROM FMI 2 – Data erratic, intermittent or incorrect Fault code explanation:

Dataset checksum fault

Fault indication:

Yellow alarm status

Fault stored in memory:

Yes

Symptom: Suitable action:

The engine cannot be started. 1 Repr Reprogr ogram am engi engine ne ECU. ECU.

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MID 128, PID 98 Engine oil level MID 128: Engine control unit FMI 1 – Data valid but below operational range Fault code explanation: Fault indication:

Oil level too low. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

Oil level level warni warning ng flashe flashes s in ala alarm rm panel panel + aud audibl ible e warn warning ing..

Symptom:

None

Preconditions:

Oil level too low.

Suitable action:

1 Check Check the the oil oil level level iin n th the e engin engine. e. 2 Chec Check k th that at no no leak leakag age e occu occurs. rs. 3 Chec Check k th the e se sens nsor or..

FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Current below normal or open circuit.

Possible reason:

Suitable action:

•

Open circui circuitt in the sensor sensor 5 V sup supply ply cable. cable.

•

Faulty sensor.

1 Check the cable cable harness harness between the s sensor ensor and tthe he EM EMS S 2. 2 Level sensor: sensor: Check contact contact press pressure ure in socket sockets s 3 and and 4 in engine connector B. 3 Chec Check k th the e se sens nsor or..

D9, D11, D12

D9CC, D13, D16

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Circuit description D9CC

D9CC, D13, D16 The oil temperature and oil level sensor is a combined sensor. The oil level sensor is supplied by a pulse of  approximately 250 mA for approx 600 ms, and the voltage drop over the sensor is read off three times during this interval. In order to obtain oil level, oil temperature must be used as a reference because oil level sensor output changes depending on oil temperature.

P0010640

D16 b

3 10

GN/SB SB

4

1 2 3 c

4 GN/W

a

a Connector A b Connector B 31

EMS2 P0008588

D13

P0010638

GR/OR

c Oil temper temperatur ature ea and nd level level sen sensor  sor 

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D9, D12

D9, D11, D12 Engine lubricating oil level is overseen by a level monitor. The level monitor output signal – monitor pin 3 to engine control unit pin 7 (pin 26 on D11) – is at one of two voltage levels, high or low. The output signal has a potential of zero if an acceptable oil level is detected. Engine control unit pin 57 (or pin 60 on D11) supplies monitor pin 1 with power. Monitor pin 2 is connected to battery negative via engine control unit pin 10.

EMS2

a

Oi Oill le leve vell mo moni nito tor  r 

b

Connector B

D11 a (-)10 (+)57,60

SB R/BL a ConnectorA 2 c

1

b

3 26

b Connector B c Oi Oill llev evel el moni monito tor  r 

GN/W

P0008587

Measurements Checking supply cable, oil level switch, page 164 Checking negative cable, oil level switch, page 164 Checking the oil level switch, page 165  Checking the oil level sensor, page 166 

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MID 128, PID 100 Engine oil pressure MID 128: Engine control unit FMI 1 – Data valid but below operational range Fault code explanation: Fault indication:

Oil pressure too low. •

Warnin Warning g is disp display layed ed in the tacho tachomet meter/ er/dis displa play. y.

Symptom:

• Oil press pressure ure warni warning ng flashe flashes s in ala alarm rm panel panel + aud audibl ible e warn warning ing.. Engine is derated.

Preconditions:

Oil pressure too low.

Conditions for fault code:

Oil pressure depends on engine speed. Oil pressure lower than the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Suitable action:

1 Check the oil oil level level in in the engine and tthe he oi oill qual quality. ity. 2 Chec Check k th that at no no leaka leakage ge o occ ccur urs. s. 3 Check that that the oil oil filters filters are not blo blocked. cked. Change Change oi oill filte filters rs and engine engine oil. 4 Check the sensor sensor by checking checking the engine engine oil pressur pressure. e. 5 Check ifif the safety safety valve valve or the the pressure pressure reli relief ef valve valve is stu stuck ck open. open.

FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Preconditions:

 Abnormally high voltage or short circuit to higher voltage has been detected.

Conditions for fault code:

Voltage on engine control unit pin B 11 exceeds 4.95 volts.

Possible reason:

Suitable action:

•

Short circuit circuit bet between ween the the sensor sensor signal cable and the the sensor sensor 5 V su supply pply cable or battery voltage.

•

Faul ultty sensor nsor..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Chec Check k th the e sens sensor or..

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FMI 5 – Current below normal or open circuit Faulty sensor/Fault in sensor circuit.

Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Current below normal or open circuit.

Conditions for fault code:

Voltage on engine control unit pin B 11 lower than 0.07 volts.

Possible reason:

•

Open Open cir circu cuit it in 5 V supp supply ly cabl cable. e.

•

Open Open cir circu cuit it in signa signall cab cable le..

•

Short circuit circuit betw between een the the sensor sensor si signal gnal c cable able and the the sensor sensor 5 V sup supply ply cable or battery voltage.

•

Short circuit circuit betw between een the the sensor sensor signal signal cable and tthe he sen sensor sor n negativ egative e cable.

•

Faulty sensor.

1 Check cables and connector connectors s betw between een the sensor and en engine gine control control unit.

Suitable action:

2 Check contact contact pressure pressure in socket 11, engine engine connector connector B, and socket 7 in engine connector A. 3 Chec Check k th the e se sens nsor or..

D9, D11, D12 a (+)7 R (-)11 SB

Circuit description c 4

1 3

31

P2

GR / OR

EMS2 b 11

BL / OR

The oil pressure sensor is a combined sensor that also measures oil temperature. There are combined sensors on D9, D11 and D12 engines; D13 and D16 engines have a separate oil temperature sensor. The sensor is of active type, i.e. it must be supplied with operating voltage. Engine control unit connector A, pin 7, supplies sensor  pin 1 with +5 volts. Sensor pin 4 is connected to batter  negative via engine control unit connector A, pin 11. The pressure sensor output signal – sensor pin 2 to engine control unit connector B, pin 11 – is a voltage

P0007206

a

Connector A

b

Connector B

c

Oil press pressure ure/te /tempe mperat rature ure sensor  sensor 

  D13 b

signal proportional to the oil pressure measured by the sensor. The output signal is linear within sensor  working range. D16 a

17 R SB 18

4

P2 a

11

(+)7 (-)11

1

P0017175

11

BL / OR

P0017176

P0017175

a b

Oi Oill pre press ssur ure e sen senso sor  r  Connector B

4

a

Connector A

b

Connector B

c

Oi Oill p pre ress ssur ure e sen senso sor  r 

1

P2 c

EMS2 b

BL / OR

EMS2

R SB

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Component specification Working range Power supply

V

0–700 kPa (0–7 bar) 5.00 ± 0.25 VDC

Nominal output voltage at 25 °C (77 °F) and supply voltage 5.00 VDC: 0.5 VDC at 0 kPa (0 bar) 4.5 VDC at 700 kPa (7 bar) NOTICE! At NOTICE!  At normal atmospheric pressure kPa

P0007192

V kPa

Output voltage Oil Pressure

 

Measurements Checking supply cable, oil pressure sensor, page 172  Checking negative cable, coolant pressure sensor, page 155  Checking signal cable, oil pressure sensor, page Checking the 172  oil pressure sensor, page 173

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MID 128, PID 105 Intake manifold temperature MID 128: Engine control unit FMI 0 – Data valid but above normal operational range Fault code explanation: Fault indication:

Excessive intake manifold temperature. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

A red lamp lamp fl flash ashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

Engine is derated

Preconditions:

Intake manifold temperature is too high

Conditions for fault code:

Intake manifold temperature exceeds the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Suitable action:

1 Check that engine engine temperat temperature ure and coolan coolantt tempe temperature rature are normal. normal. 2 Chec Check k th the e se sens nsor or..

FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit. •

Warnin Warning g is disp display layed ed in tthe he tacho tachomete meter/d r/disp isplay lay..

•

An orange orange lamp lamp flashe flashes s in in the the alarm alarm displa display. y.

Symptom:

None

Preconditions:

The voltage is less than the normal value or is short circuited to battery negative.

Conditions for fault code:

Voltage on engine control unit pin A47 lower than 0.07 volts.

Possible reason:

Suitable action:

•

Short circuit circuit bet between ween the sensor sensor signal cable and tthe he sen sensor sor n negativ egative e cable.

•

Faulty se sensor 

1 Check cables and connectors connectors between the se sensor nsor and and engine engine control control unit. 2 Ch Chec eck k th the e sens sensor or..

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FMI 5 – Current below normal or open circuit Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Preconditions:

Current below normal or open circuit.

Conditions for fault code:

Voltage on engine control unit pin A47 exceeds 4.95 volts.

Possible reason:

Suitable action:

•

Short circuit circuit bet between ween the the sensor sensor signal cable and the the sensor sensor 5 V su supply pply cable or battery voltage.

•

Open Open circ circui uitt iin n sig signa nall cab cable le..

•

Faulty se sensor 

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Check contact contact pressure pressure in so socket cket 47 in engine connec connector tor A A.. 3 Chec Check k th the e sens sensor or..

D9, D12

D11, D13, D16

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D9, D12

Circuit description

a

ConnectorA

b

Air inle inlett p press ressure/i ure/intake ntake mani manifold fold temperature temperature

  D11, D13, D16 a

The intake manifold temperature sensor comprises a thermistor that forms a closed circuit with an internal resistor in the engine control unit (EMS2). Thermistor  resistance changes non-linearly depending on intake manifold temperature. EMS2 supplies the circuit with a reference voltage of +5 volts. EMS2 measures the voltage drop across the thermistor via EMS2 pins 47 and 11. Sensor pin 1 is connected to battery negative via EMS2 pin 11. When intake manifold temperature temp erature is cold thermistor resistance is high and EMS2 detects a high voltage drop. As intake manifold temperature rises thermistor resistance falls and voltage drop is reduced. Refer to the Resistance/temperature table in this fault code chapter.

b

P0007209

a

ConnectorA

b

Air inle inlett p press ressure/i ure/intake ntake mani manifold fold temperature temperature

 

Measurements Checking negative cable, intake manifold temperature sensor, page 170  Checking signal cable, intake manifold temperature sensor, page 170  Checking the intake manifold temperature sensor, page 171

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MID 128, PID 106 Air inlet pressure MID 128: Engine control unit FMI 0 – Data valid but above normal operational range Fault code explanation: Fault indication:

 Air inlet pressure too high. •

Warnin Warning g is disp display layed ed in the tacho tachomet meter/ er/dis displa play. y.

Symptom:

• A red lamp lamp flash flashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng. Engine is derated.

Preconditions:

 Air inlet pressure too high.

Conditions for fault code:

Charge air pressure exceeds the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Suitable action:

1 Check the compresso compressorr unit. unit. The turbocharger turbocharger must comply comply w with ith the specification for the engine. 2 Check Check the sens sensor or by checki checking ng the air air inle inlett pressur pressure. e. 3 Check Check the the wast wastega egate te valv valve e fu funct nction ion.. NOTICE! Only NOTICE!  Only applicable to D12.

FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Preconditions:

Voltage above normal or shorted high

Conditions for fault code:

Voltage on engine control unit pin A22 exceeds 4.95 volts.

Possible reason:

Suitable action:

•

Short circuit circuit bet between ween sensor sensor signal cable and s sensor ensor supply cable or  battery voltage

•

Open Open circu circuit it in in th the e senso sensorr ne negati gative ve c cable able..

•

Faul ultty sensor nsor..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Check contact contact pressure pressure in so socket cket 11 in engine connec connector tor B B.. 3 Chec Check k th the e sens sensor or..

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FMI 5 – Current below normal or open circuit Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Current below normal or open circuit

Conditions for fault code:

Voltage on engine control unit pin A22 lower than 0.07 volts.

Possible reason:

Suitable action:

•

Open Open cir circu cuit it in 5 V supp supply ly cabl cable. e.

•

Open Open cir circu cuit it in signa signall cab cable le..

•

Short circuit circuit bet between ween the the sensor sensor p power ower 5 V supp supply ly cable cable and and the sensor  negative cable.

•

Faulty sensor.

1 Check cables and connector connectors s betw between een the sensor and en engine gine control control unit. 2 Check contact contact pressure pressure in socket sockets s 22 and and 7 in engine connec connector tor A. 3 Chec Check k th the e se sens nsor or..

D9. D12

D11, D13, D16

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D9, D12

 

Circuit description

a

ConnectorA Color: Black

b

Air inle inlett p pressu ressure/in re/intake take mani manifold fold temperatur temperature e

  D11, D13, D16

The charge air pressure sensor is a combined sensor  that also measures intake manifold air temperature. The sensor is of active type, i.e. it must be supplied with operating voltage. Engine control unit pin 7 supplies sensor pin 1 with +5 volts. Sensor pin 4 is connected to battery b attery negative via engine control unit connector pin 11. The pressure sensor output signal – sensor pin 2 to engine control unit connector A, pin 22 – is a voltage signal proportional to the pressure measured by the sensor. The output signal is linear within sensor  working range.

Component specification D9, D12 Working range Power supply

40–400 kPa (0.4–4.0 bar) 5.00 ± 0.25 VDC

Nominal output voltage at 25 °C (77 °F) and supply voltage 5.00 VDC: 0.5 VDC at 40 kPa (0.4 bar)

 

a

ConnectorA

b

Air inle inlett p pressu ressure/in re/intake take mani manifold fold temperatur temperature e

c

Joint

4.5 VDC at

400 kPa (4 bar)

D11, D16 Working range Power supply

50–400 kPa (0.5–4.0 bar) 5.00 ± 0.25 VDC

Nominal output voltage at 25 °C (77 °F) and supply voltage 5.00 VDC: 0.5 VDC at 50 kPa (0.5 bar) 4.5 VDC at 400 kPa (4 bar) D13 Working range Power supply

50–600 kPa (0.5–6.0 bar) 5.00 ± 0.25 VDC

Nominal output voltage at 25 °C (77 °F) and supply voltage 5.00 VDC: 0.5 VDC at 50 kPa (0.5 bar) 4.5 VDC at 600 kPa (6 bar)

Measurements Checking negative cable, air inlet pressure sensor, page 178  Checking signal cable, air inlet pressure sensor, page 178  Checking the air inlet pressure sensor, page 179 Checking supply cable, air inlet pressure sensor, page 179

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MID 128, PID 110 Engine coolant temperature MID 128: Engine control unit FMI 0 – Data valid but above normal operational range Fault code explanation: Fault indication:

Coolant temperature too high • •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y. The warni warning ng sym symbol bol in the the alarm alarm panel panel fl flashe ashes s red. T The he coo coolan lantt temperature symbol in the alarm panel flashes red. Audible warning.

Symptom:

Engine is derated.

Preconditions:

Coolant temperature too high

Conditions for fault code:

Coolant temperature exceeds the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Possible reason:

Suitable action:

•

Lo Low w co cool olan antt llev evel el..

•

Bloc Blocke ked ds sea eawa wate terr fi filt lter  er 

•

Worn Worn im impel pelle lerr iin n sea seawa wate terr pump pump

•

Pinche Pinched, d, leakin leaking g or bloc blocked ked hose hose on the s suct uction ion si side de (se (seawa awater) ter)..

•

Defe Defect ctiv ive e th ther ermo most stat at

•

Bloc Blocke ked dh hea eatt e exc xcha hang nger  er 

•

Poor Poor fflo low w in in tthe he coo cooli ling ng sys system tem

•

Worn Worn coo oollan antt pu pump mp

•

Defect Defective ive pressur pressure e cap, cap, expansi expansion on tank. tank.

•

Defect Defective ive tempera temperature ture sensor sensor,, coolant coolant..

1 Chec Check k the the cool coolan antt llev evel el.. 2 Check Check that that the system system does does no nott le leak. ak. 3 Check Check that that the seaw seawate aterr filter filter is is not block blocked. ed. 4 Remove the reverse reverse gear gear oi oill cool cooler er end plate and check check wh whether ether tthe he oil cooler is clogged. 5 Check Check the the impell impeller er in the the seawa seawater ter p pump ump.. 6 Check Check the the coola coolant nt temp temperat erature ure sensor. sensor. 7 Clean Clean the heat heat exch exchange angerr in th the e cooling cooling s syst ystem. em.

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FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

Or Orang ange e lamp lamp fla flash shin ing g in a ala larm rm pane panel. l.

Symptom:

None

Preconditions:

The voltage is less than the normal value or is short circuited to battery negative.

Conditions for fault code: Possible reason:

Voltage on engine control unit pin B27 lower than 0.07 volts. • Short circuit circuit bet between ween the the sensor sensor signal cable and th the e sen sensor sor negative negative cable. •

Suitable action:

Faul aulty sensor nsor..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Chec Check k th the e sens sensor or..

FMI 5 – Current below normal or open circuit Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

Or Oran ange ge lamp lamp fla flash shin ing g in a ala larm rm pane panel. l.

Symptom:

None

Preconditions:

Current below normal or open circuit.

Conditions for fault code:

Voltage on engine control unit pin B27 exceeds 4.95 volts.

Possible reason:

Suitable action:

•

Open Open circ circui uitt iin n sig signa nall cab cable le..

•

Open Open circu circuit it in in th the e senso sensorr ne negati gative ve c cable able..

•

Faul ultty sensor nsor..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Check contact contact pressure pressure in sockets sockets 18 and and 27 in in engine engine connector connector B. 3 Chec Check k th the e sens sensor or..

D9, D12, D16

D11, D13

p0004941

95

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b

Circuit description a

GR / W

P0007217

 

a

Co Cool olan antt temp temper erat atur ure e se sens nsor  or 

b

Connector B

The coolant temperature sensor consists of a thermistor that forms a closed circuit with the engine control unit. A thermistor characteristic is that its resistance changes non-linearly in relation to the temperature of the medium it measures. Engine control unit B, pin 27, supplies sensor pin 1 with a reference voltage of +5 volts. Sensor pin 2 is connected to battery negative via engine control unit connector pin 18. When the coolant is cold thermistor resistance is high and the control unit senses a voltage close to the reference level. As coolant temperature rises thermistor resistance falls and the voltage drop is reduced. Refer to the resistance/temperature table.

Measurements Checking negative cable, coolant temperature sensor, page 180  Checking signal cable, coolant temperature sensor, page 181 Checking the coolant temperature sensor, page 182 

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MID 128, PID 111 Coolant level MID 128: Engine control unit FMI 1 – Data valid but below operational range Fault code explanation: Fault indication:

Coolant level too low •

Warnin Warning g is disp display layed ed in the tacho tachomet meter/ er/dis displa play. y.

Symptom:

• Coolan Coolantt indic indicato atorr lamp lamp flash flashing ing in a alar larm m panel. panel. None

Conditions for fault code:

Coolant level too low

Possible reason:

Suitable action:

•

Lo Low w coo coola lant nt leve level. l.

•

Coolant lle eakage

•

Short Short circu circuit it betwe between en pin pin B23 and and batte battery ry ne negat gative ive..

•

Fa Faul ulty ty cool coolant ant leve levell s swi witc tch h

1 Chec Check k tthe he cool coolan antt llev evel el.. 2 Chec Check k th that at no no leaka leakage ge o occ ccur urs. s. 3 Check Check the the wiring wiring to to the coola coolant nt le level vel s swit witch. ch. 4 Chec Check k the the le leve vell swi switc tch. h.

FMI 3 – Voltage above normal or shorted high Fault code explanation:

Faulty sensor/Fault in sensor circuit.

Fault indication:

None

Symptom:

None

Preconditions:

 Abnormally high voltage or short circuit to higher voltage has been detected.

Conditions for fault code:

Excessive voltage on engine control unit pin B23.

Possible reason:

Short circuit to battery voltage on pin B23.

Suitable action:

 

1 Check the cable cable harness harness between between the the coola coolant nt level level switch switch and the EMS 2.

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b

Circuit description a

P0007222

 

a

Co Cool olan antt leve levell moni monito tor  r 

b

Connector B Color: GrAy

Engine coolant level is overseen by a level monitor. Engine control unit connector B, pin 23, supplies sensor pin 1 with power at approximately 0.8 x battery voltage. Level monitor pin 2 is connected to battery negative via engine control unit pin 10. The level monitor has two states: infinite resistance or zero resistance. The level monitor comprises two parts, the actual monitor and a magnetic float built into the expansion tank. The monitor senses the position of the magnetic float. When coolant level drops, the float acts on the level monitor whose resistance drops to zero whereupon a closed circuit is formed.

Measurements Checking supply cable, coolant switch, page 182  Checking negative cable, coolant switch, page 183 Checking the coolant switch, page 183

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MID 128, PID 153 Crankcase pressure MID 128: Engine control unit FMI 0 – Data valid but above normal operational range Fault code explanation: Fault indication:

Crankcase pressure too high • •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay. A red lamp lamp flash flashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

Engine is derated and limited to 1200 rpm.

Preconditions:

Crankcase pressure too high

Conditions for fault code:

Rapid increase in crankcase pressure (For power loss, refer to the engine protection folder for parameters.)

Possible reason:

Suitable action:

•

Fa Faul ultt iin n sen senso sorr c cab able les. s.

•

Worn Worn or damage damaged d cylind cylinder er liliners ners,, pis pistons tons or or piston piston ri rings ngs

•

Bloc Blocke ked d cr cran ankc kcas ase e ve vent ntil ilat atio ion n

•

Faul ultty sensor nsor..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Check Check and clean clean the cr crank ankcas case e ventila ventilatio tion n system. system. 3 Check the sensor sensor by checking checking the fuel fuel crankcas crankcase e pres pressure. sure.

FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Preconditions:

Voltage above normal or shorted high

Conditions for fault code:

Voltage on engine control unit pin B28 exceeds 4.78 volts.

Possible reason:

Suitable action:

•

Short circuit circuit bet between ween the the sensor sensor signal cable and the the sensor sensor 5 V su supply pply cable or battery voltage.

•

Open Open circu circuit it in in th the e senso sensorr ne negati gative ve c cabl able. e.

•

Faul aulty sensor nsor..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Check contact contact pressure pressure in so socket cket 18 in engine connec connector tor B B.. 3 Chec Check k th the e sens sensor or..

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FMI 5 – Current below normal or open circuit Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Current below normal or open circuit.

Conditions for fault code:

Voltage on engine control unit pin B28 lower than 0.30 volts.

Possible reason:

Suitable action:

•

Open Open cir circu cuit it in 5 V supp supply ly cabl cable. e.

•

Open Open cir circu cuit it in signa signall cab cable le..

•

Short circuit circuit betw between een the the sen sensor sor signal signal cable cable and tthe he sen sensor sor n negativ egative e cable.

•

Faulty sensor.

1 Check cables and connector connectors s betw between een the sensor and en engine gine control control unit. 2 Check contact contact pressure pressure in socket sockets s 17 and and 28 iin n engine engine connector connector B B.. 3 Check s se ensor.

 

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b

Circuit description a

GN / R

P0007226

a

Cr Cran ankc kcas ase e pres pressu sure re s sen enso sor  r 

b

Connector B

 

The crankcase pressure sensor is of active type, i.e. it must be supplied with operating voltage. Engine control unit pin 17 supplies sensor pin 1 with +5 volts. Sensor pin 4 is connected to battery negative via engine control unit connector pin 18. The pressure sensor output signal – sensor pin 2 to control unit B, pin 28 – is a voltage signal that is proportional to crankcase pressure. The output signal is linear within sensor working range. The alarm is triggered depending on how quickly crankcase pressure rises.

Component specification Working range Power supply

40–140 kPa (0.4–1.4 bar) 5.00 ± 0.25 VDC

Nominal output voltage at 25 °C (77 °F) and supply voltage 5.00 VDC: 0.5 VDC at 40 kPa (0.4 bar) 4.5 VDC at 140 kPa (1.4 bar) V kPa

Output voltage Crankcase pressure

 

Measurements Checking supply cable, crankcase pressure sensor, page 184 Checking negative cable, crankcase pressure sensor, page 184 Checking signal cable, crankcase pressure sensor, page 185  Checking the crankcase pressure sensor, page 185 

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MID 128, PID 158 ECU battery potential MID 128: Engine control unit NOTICE! This fault code might be set due to incorrect NOTICE! This voltage value settings, depending on the installation. This value can be adjusted in VODIA.

FMI 1 – Data valid but below operational range Fault code explanation: Fault indication:

Value too low. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

•

Battery Battery indica indicator tor llamp amp flashi flashing ng iin n al alarm arm p pane anel. l.

Symptom:

None

Preconditions:

Data valid but below operational range.

Conditions for fault code:

Possible reason:

Suitable action:

•

Battery Battery volt voltage age lo lower wer than than 13 13.2 .2 V wh while ile engi engine ne run runnin ning. g. (Applies to 12 V system).

•

Battery Battery volt voltage age lo lower wer than than 25 25.5 .5 V wh while ile engi engine ne run runnin ning. g. (Applies to 24 V system).

• •

Altern Alternator ator drive drive belt, belt, alte alterna rnator tor n not ot charg charging ing.. Fault Fault in battery battery,, cabl cables es or con connec nectors tors..

•

Faul Faulty ty alte altern rnat ator  or 

•

Faul Faulty ty se sens nsor or ca cabl ble e

1 Check Check that the alterna alternator tor cha charges rges.. 2 Chec Check k tthe he sens sensor or cabl cable. e. 3 Check the battery battery cables and the the battery battery connec connections. tions. 4 Chec Check/ k/ch charg arge e the b batt atter erie ies. s.

Circuit description EMS2 monitors voltage supply at pins B57 and B60.

 

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MID 128, PID 163, Transmission range attained MID 128: Engine control unit FMI 9 – Abnormal update rate Fault code explanation:

Communication fault

Fault indication: Symptom:

 An orange lamp flashes in the alarm panel. None

Conditions for fault code:

Timeout in communication on the secondary bus J1587.

Possible reason:

Suitable action:

•

Br Brea eak k in com commu muni nica cati tion on from from tthe he PCU PCU..

•

Faulty PCU

1 Check the communic communication ation cables cables betwee between n the e engine ngine and the PCU. 2 Check that the the PCU is programmed programmed for the correct correct engin engine e type. type.

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MID 128, PID 173 Exhaust gas temperature D11, D13, D16, D9

MID 128: Engine control unit FMI 0 – Data valid but above normal operational range Fault code explanation: Fault indication:

Exhaust temperature too high • Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y. •

A red lamp lamp fl flash ashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

None

Preconditions:

Exhaust temperature too high

Conditions for fault code:

Exhaust temperature exceeds the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Suitable action:

1 Check that the the exhaust exhaust pipe pipe has not bee been n damaged damaged and that tthere here are are no restrictions. 2 Chec Check k th the e se sens nsor or.. 3 Check Check the exhaus exhaustt back back pressure pressure..

FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Voltage below normal or shorted to lower voltage

Conditions for fault code:

Voltage on engine control unit pin B44 lower than 0.07 volts.

Possible reason:

Suitable action:

•

Short circuit circuit betw between een the the sensor sensor signal signal cable and tthe he sen sensor sor n negativ egative e cable.

•

Faulty sensor.

1 Check the cable cable harness harness between the s sensor ensor and tthe he EM EMS S 2. 2 Chec Check k th the e se sens nsor or..

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FMI 5 – Current below normal or open circuit Faulty sensor/Fault in sensor circuit

Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Preconditions:

Current below normal or open circuit.

Conditions for fault code:

Voltage on engine control unit pin B44 exceeds 4.95 volts.

Possible reason:

•

Open Open cir circu cuit it iin n sens sensor or si signa gnall ca cabl ble. e.

•

Open Open circ circuit uit in sensor sensor negati negative ve cab cable. le.

•

Faul ultty sensor nsor..

1 Check the cable cable harness between between the sensor and th the e EMS 2.

Suitable action:

2 Check contact contact pressure pressure in sockets sockets 18 and and 44 in in engine engine connector connector B. 3 Chec Check k th the e sens sensor or..

D9 CC, D16

Circuit description

Conn. B (-) 18 (+) 44

SB VO

        1

1

1 2         2

2

EMS2 D11 Conn. B (-) 18 (+) 44

SB BN

        2

2

2 1         1

The exhaust temperature sensor is a Pt 200 sensor  whose resistance changes depending on exhaust temperature. Resistance increases as exhaust temperature rises. Engine control unit (EMS2) connector B, pin 44, supplies operating power of +5 volts to sensor pin 2 (D11; pin 1). Sensor pin 1 (D11; pin 2) is connected to battery negative via EMS2 pin 18. The voltage drop across the sensor changes as exhaust temperature changes.

1

EMS2 D13 Conn. B         1   1

1 2

(-) 18 SB (+) 44

GR

        2

2

EMS2 P0007230

 

Measurements Checking signal cable, exhaust temperature sensor, page 186  Checking negative cable, exhaust temperature sensor, page 186  Checking exhaust temperature sensor, page 187 

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MID 128, PID 175 Engine oil temperature D11, D12, D9

MID 128: Engine control unit FMI 0 – Data valid but above normal operational range Fault code explanation: Fault indication:

Engine oil temperature too high • Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y. •

A red lamp lamp fl flash ashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

Engine is derated.

Preconditions:

Engine oil temperature too high

Conditions for fault code:

Oil temperature exceeds the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Suitable action:

1 Check Check the the oil oil level level iin n th the e engin engine. e. 2 Check Check the coola coolant nt level level and the the engine engine te temper mperatu ature. re. 3 Chec Check k th that at no lea leaka kage ge occ occurs urs.. 4 Chec Check k th the e se sens nsor or.. 5 cooler. Clean the oil cooler system and check check the bypass valve for th the e oil For more detailed instructions, refer to Workshop manual group 22, Lubrication system.

FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Voltage below normal or shorted to lower voltage

Conditions for fault code:

Voltage on engine control unit pin A31 lower than 0.07 volts.

Possible reason:

Suitable action:

•

Short circuit circuit betw between een the the sensor sensor signal signal cable and tthe he sen sensor sor n negativ egative e cable.

•

Faulty se sensor 

1 Check cables and connector connectors s betw between een the sensor and en engine gine control control unit. 2 Check s se ensor.

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FMI 5 – Current below normal or open circuit Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Preconditions:

Current below normal or open circuit.

Conditions for fault code:

Voltage on engine control unit pin A31 exceeds 4.95 volts.

Possible reason:

Suitable action:

•

Short circuit circuit bet between ween the the sensor sensor signal cable and the the sensor sensor 5 V su supply pply cable or battery voltage.

•

Open Open circ circui uitt iin n sig signa nall cab cable le..

•

Open Open cir circu cuit it iin n sens sensor or ne nega gati tive ve cab cable le

•

Faul aulty sensor nsor..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Check contact contact pressure pressure in socket 11, engine engine connecto connectorr A, a and nd socket socket 11 in engine connector B. 3 Chec Check k th the e sens sensor or..

 

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a (+)7 (-)11 31

c R SB GR / OR

EMS2 b 11

BL / OR

4

1 3 P2

Circuit description The oil temperature sensor is a combined sensor that also measures oil pressure.  A thermistor characteristic is that its resistance changes non-linearly in relation to the temperature of  the medium it measures. If the oil in the engine is cold, thermistor resistance is high. If the oil temperature rises, thermistor resistance drops. The voltage drop

P0007206

a

 

ConnectorA Color: Black

b

Connector B Color: GrAy

c

Oi Oill te temp mper erat atur ure e sens sensor  or 

across the thermistor changes as oil temperature changes. The voltage drop is detected via pin 31 on the engine control unit. Engine control unit pin 7 supplies sensor  pin 1 with +5 volts. Sensor pin 4 is connected to battery batter y negative via engine control unit connector pin 11. Refer to the "resistance/temperature, engine" table.

Measurements Checking negative cable, oil temperature sensor, page 188  Checking power supply cable, oil temperature sensor, page 189 Checking the oil temperature sensor, page 190 

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MID 128, PID 175 Engine oil temperature D13, D16

MID 128: Engine control unit FMI 0 – Data valid but above normal operational range Fault code explanation: Fault indication:

Engine oil temperature too high • Warnin Warning g is disp display layed ed in the tacho tachomet meter/ er/dis displa play. y. •

A red lamp lamp flas flashes hes iin n the alarm alarm disp display lay + a audi udible ble w warn arning ing..

Symptom:

Engine is derated.

Preconditions:

Engine oil temperature too high

Conditions for fault code:

Engine oil temperature exceeds the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Suitable action:

1 Check Check the the oil oil leve levell in the engine. engine. 2 Check Check the cool coolant ant level level and and the en engin gine e temp temperat erature ure.. 3 Chec Check k th that at no no leaka leakage ge o occ ccur urs. s. 4 Chec Check k th the e sens sensor or.. 5 Clean the oil oil cooler cooler sys system tem and check the bypass bypass valve valve for for the oil cooler. For more detailed instructions, refer to Workshop manual group 22, Lubrication system.

FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Preconditions:

Voltage below normal or shorted to lower voltage

Conditions for fault code:

Voltage on engine control unit pin A31 lower than 0.07 volts.

Possible reason:

Suitable action:

•

Short circuit circuit bet between ween the the oil oil tem temperatur perature e sig signal nal cable cable to the sensor  negative cable.

•

Short circuit circuit bet between ween oil oil ttemperat emperature ure si signal gnal cable and tthe he sen sensor sor 5 V supply cable.

•

Short circuit circuit bet between ween oil oil ttemperat emperature ure si signal gnal cable and oi oill level level signal signal cable.

•

Faulty se sensor 

1 Check the cable cable harness between between the sensor and th the e EMS 2. 2 Chec Check k th the e sens sensor or..

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FMI 5 – Current below normal or open circuit Fault code explanation: Fault indication:

Faulty sensor/Fault in sensor circuit •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

Current below normal or open circuit.

Conditions for fault code:

Voltage on engine control unit pin A31 exceeds 4.95 volts.

Possible reason:

Suitable action:

•

Open circui circuitt in tthe he oil oil tempera temperatur ture e sig signal nal cabl cable. e.

•

Open circui circuitt in the sensor sensor negati negative ve c cabl able. e.

•

Faulty sensor.

1 Check the cable cable harness harness between the s sensor ensor and tthe he EM EMS S 2. 2 Check contact contact pressure pressure in socket 10, engine engine connector connector B, and socket 31 in engine connector A. 3 Chec Check k th the e se sens nsor or..

 

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Circuit description The oil temperature and oil level sensor is a combined sensor. The oil temperature sensor comprises a thermistor  that forms a closed circuit with an internal resistor in the EMS. Thermistor resistance changes according to a non-linear characteristic depending on oil temperature.

D13

The EMS supplies the circuit with a reference voltage of +5 V via pin A31. The EMS measures the voltage drop across the thermistor via pin B10 and A31 for  D16 and pin A11 and A31 for D13. Sensor pin 4 is connected to battery negative via the EMS. When oil temperature is cold thermistor resistance is high and the EMS detects a high voltage drop. As coolant temperature rises thermistor resistance falls and the voltage drop is reduced.

P0010638

D16 b c

a

P0007204

a

Connector B

b

ConnectorA

c

Oi Oill tem tempe pera ratu ture re an and d llev evel el

Measurements Checking negative cable, oil temperature sensor, page 191 Checking signal cable, oil temperature sensor, page 192  Checking the oil temperature sensor, page 193

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MID 128, PID 190 Engine speed MID 128: Engine control unit FMI 0 – Data valid but above normal operational range Fault code explanation: Fault indication:

The engine control unit has detected that engine speed is above the specified threshold value. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

A red lamp lamp fl flash ashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

None

Preconditions:

The engine control unit has detected that engine speed is above the specified threshold value.

Conditions for fault code:

The engine is overspeeding.

Suitable action:

1 After the the engine engine has stopped stopped,, sear search ch for the reason reason fo forr the hi high gh speed. speed.

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MID 128, PPID 3 Starter Output MID 128: Engine control unit FMI 3 – Voltage above normal or shorted high FMI 4 – Voltage below normal or shorted to lower voltage FMI 5 – Current below normal or open circuit Fault code explanation: Fault indication:

Faulty relay/Faulty relay circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

The starter motor is not activated.

Preconditions:

General checks for starter motor problems: •

Check Check the the start starter er moto motorr cables cables and con connec nectio tions. ns.

•

Check that the pre-start pre-start and start start relay relay pull during a start start att attempt. empt.

Conditions for fault code:

Faulty pre-start or start relay

Suitable action:

NOTICE! See correct wiring diagram for prestart / start relay wiring. 1 Check that the the pre-start pre-start and and sta start rt relay relay pull during a start attempt attempt.. 2 Check the cables cables between between the en engine gine c control ontrol unit a and nd the start relay. 3 Check contact contact pressure pressure in so socket cket B29 in in engine engine c connecto onnector. r. 4 Check that socket socket B29 in the engine engine connecto connectorr is no nott pushed pushed in.

Circuit description When ignition is on the potential on pin B29 is approximately 10 V. When cranking is requested B29 is connected, via the EMS, to battery negative and the starter motor is engaged. NOTICE! See correct wiring diagram for prestart / start NOTICE! See relay wiring.

Measurements Checking the starter motor solenoid, page 194 Checking the pre-start relay, page 194

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MID 128, PPID 6 Key off input sensor  MID 128: Engine control unit FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation:

Faulty relay/Faulty relay circuit •

Fault indication:

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

Symptom:

• An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay. Engine stops or cannot be started.

Preconditions:

Voltage below normal or shorted to lower voltage

Conditions for fault code:

Voltage on engine control unit pin A27 lower than 0.375 volts.

Possible reason:

Short circuit to battery negative in cable from EMS2 pin A27 to the external stop relay.

Suitable action:

1 Check the cable cable between between EMS2 EMS2 pi pin n A27 to the externa externall stop relay connector.

FMI 11 – Unidentifiable error  Fault code explanation: Fault indication:

Stop input is activated. • •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y. A red lamp lamp fl flash ashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

Engine stops or cannot be started.

Preconditions:

Stop input is activated.

Conditions for fault code:

Voltage on engine control unit pin A27 higher than 23.2 volts.

Possible reason:

Suitable action:

•

Th The e sto stop p rrel elay ay is acti activa vate ted. d.

•

Faul Faulty ty stop stop rela relay y

•

Faul Faulty ty rela relay yc cab able les s

•

Short Short circui circuitt between between the the sign signal al cab cable le to bat batter tery y posi positiv tive. e.

1 Check what triggere triggered d activation activation of the stop re relay, lay, fire fire alarm. alarm. 2 Check Check the conne connecto ctorr that ac activ tivate ates s the stop stop rel relay. ay. 3 Chec Check k tthe he sto stop p rrel elay ay.. 4 Check cables and connector connectors s betw between een the control unit and and the relay socket.

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Circuit description  A classified electrical system has no external stop relay as standard, just a connector for use by an external stop relay. An external stop relay must be connected to the system.  A non-classified electrical system has an external stop relay as standard. While the stop relay is not activated the voltage potential on engine control unit connector A pin 27 is approx 0.8 x battery voltage. When the stop relay is activated pin 27 is connected to battery voltage from a terminal. When the stop relay is activated the engine control unit shuts off fuel injection. When the stop relay is activated the system must be switched off before a new start attempt can be made.

Measurements Checking the external stop voltage  potential, page page 195 

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MID 128, PPID 8 Piston Cooling Oil Pressure D11

MID 128: Engine control unit FMI 1 – Data valid but below operational range Fault code explanation: Fault indication:

Piston cooling pressure is too low. • Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y. •

A red lamp lamp fl flash ashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

Engine is derated.

Conditions for fault code:

Piston cooling pressure is too low.

Suitable action:

1 Check the sensor sensor by checking checking the piston cooli cooling ng oil pressure pressure wit with ha manometer. Be sure not to load the engine while doing this. Please refer to Administratio to Administration, n, page 9 to 9 to see at what rpm a piston cooling pressure should be expected.

FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

Defective sensor/Defect in sensor circuit • Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y. •

A red lamp lamp fl flash ashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

Engine is derated.

Conditions for fault code:

Voltage on engine control unit pin A23 exceeds 4.78 volts.

Possible reason:

Suitable action:

•

Short circuit circuit betw between een the the sensor sensor si signal gnal c cable able and the the sensor sensor 5 V sup supply ply cable or battery voltage.

•

Open circui circuitt in the sensor sensor negati negative ve c cabl able. e.

•

Faulty sensor.

1 Check cables and connector connectors s betw between een the sensor and en engine gine control control unit. 2 Check contact contact pressure pressure in so socket cket 11 in engine connec connector tor B B.. 3 Chec Check k th the e se sens nsor or..

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FMI 5 – Current below normal or open circuit Fault code explanation: Fault indication:

Defective sensor/Defect in sensor circuit •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

A red lamp lamp flash flashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

Engine is derated.

Conditions for fault code:

Engine control unit pin A23 voltage lower than 0.30 volts.

Possible reason:

Suitable action:

•

Open Open cir circu cuit it in in 5 V supp supply ly c cab able le..

•

Open Open circ circui uitt iin n sig signa nall cab cable le..

•

Short circuit circuit bet between ween the the sensor sensor signal cable and th the e sen sensor sor negative negative cable.

•

Faul ultty sensor nsor..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Check contact contact pressure pressure in sockets sockets 7 and and 23 in engine connect connector or B. 3 Chec Check k th the e sens sensor or..

 

Circuit description 23

GR/R

(+)7

R

(-)11

SB

EMS2 P0008475

 

a

Pist Piston on cool coolin ing gp pre ress ssur ure e

2 1 4 a

The sensor is of active type, i.e. it must be supplied with operating voltage. Engine control unit connector A, pin 7, supplies sensor  pin 1 with +5 volts. Sensor pin 4 is connected to battery negative via engine control unit connector A, pin 11. The pressure sensor pin 2 output signal to engine control unit pin 23 is a voltage signal proportional to piston cooling oil pressure. The output signal is linear within sensor working range.

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Component specification

V

Working range Power supply

0–700 kPa (101.5 PSI) 5.00 ± 0.25 VDC

Nominal output voltage at 25 °C (77 °F) and supply voltage 5.00 VDC: 0.5 VDC at 0 kPa (0 PSI)* P0007192

kPa

4.5 VDC at

700 kPa (101.5 PSI)*

NOTICE! * NOTICE!  * At normal atmospheric pressure.

V: Output voltage kPa: Piston cooling pressure

 

Measurements Checking negative cable, piston cooling pressure sensor, page 176  Checking power supply cable, piston cooling pressure sensor, page 177  Checking the piston cooling pressure sensor, page 177 

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MID 128, PPID 8 Piston Cooling Oil Pressure D12, D16

MID 128: Engine control unit FMI 1 – Data valid but below operational range Fault code explanation: Fault indication:

Piston cooling pressure is too low. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

A red lamp lamp flash flashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

Engine power is reduced.

Preconditions:

Piston cooling pressure is too low. 1 Check the sensor sensor by checking checking the piston coolin cooling g oil pressure pressure with a manometer. Be sure not to load the engine while doing this. Please refer to Administratio to Administration, n, pag page e 9 to 9 to see what rpm a piston cooling pressure should be expected.

Suitable action:

  SB

a 2

10 SB

14 GR / R

EMS P0007245

a

 

Pis Piston ton coolin cooling gp pres ressur sure e swi switch tch

P1

Circuit description There is a valve in the oil filter bracket that opens and closes piston cooling oil supply depending on oil pressure. If oil pressure is below 240 kPa (D12) or 300 kPa (D16) the valve closes piston cooling oil supply. Piston cooling pressure is overseen by a pressure monitor. The monitor output signal – engine control unit pin 1 – can only have one of two distinct potentials, high or low. The monitor is supplied with power by engine control unit pin 10. A specified pressure pr essure limit of 150 kPa determines when the monitor switches potential. Monitor potential is low when piston cooling pressure exceeds this value.  At idle idle the monitor may have high potential without any fault code being triggered.

Measurements Checking negative cable, piston cooling pressure sensor, page 175  Checking power supply cable, piston cooling pressure sensor, page 176 

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MID 128, PPID 98 Engine sync acknowledge MID 128: Engine control unit FMI 9 – Abnormal update rate Fault code explanation: Fault indication:

Communication fault • •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y. An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Conditions for fault code:

Timeout on J1587 of the secondary bus. The EMS does not receive any engine sync data from the PCU.

Possible reason:

Suitable action:

•

Throttle Throttle signal signal not found. found. (A fa fault ult code code is obtain obtained ed together together with MID 164, PPID 392 and MID 164, PPID 390).

•

Fault Fault in tthe he commun communica icatio tion n bet betwee ween n the E EMS MS and and the P PCU. CU.

•

Open circuit circuit in the the pow power er su supply pply cable betwee between n the engine contro controll uni unitt and the PCU.

•

Faulty PCU

1 If an HCU fault code exists exists regarding regarding the throttl throttle e lever: lever: Check that there is a signal between the throttle linkage and the HCU. 2 Check all connector connectors s and wires betwee between n the E EMS MS and the PC PCU. U. 3 Check that the the PCU is programmed programmed for the correct engine type.

 

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MID 128, PPID 117 Engine protection status FMI 7 – Mechanical system not responding properly Fault code explanation:

Engine protection mode is activated.

Fault indication:

Red alarm status

Fault stored in memory:

Yes

Symptom:

Engine is derated.

Suitable action: Logging parameter:

1 Check which which engine engine protectio protection n crite criteria ria that set this this DTC. DTC. Check for  other active DTC.: Engine protection status

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MID 128, PPID 132 Throttle Calibrated Position MID 128: Engine control unit FMI 9 – Abnormal update rate Fault code explanation: Fault indication:

Communication failure • •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y. An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

Engine goes to idle.

Conditions for fault code:

Timeout on J1587 of the secondary bus. The EMS does not receive any engine sync data from the PCU.

Possible reason:

Suitable action:

•

Throttle Throttle signal signal not found. found. (A fa fault ult code code is obtain obtained ed together together with MID 164, PPID 392 and MID 164, PPID 390).

•

Fault Fault in tthe he commun communica icatio tion n bet betwee ween n the E EMS MS and and the P PCU. CU.

•

Open circuit circuit in the the pow power er su supply pply cable betwee between n the engine contro controll uni unitt and the PCU.

•

Faulty PCU

1 If an HCU fault code exists exists regarding regarding the throttl throttle e lever: lever: Check that there is a signal between the throttle linkage and the HCU. 2 Check all connector connectors s and wires betwee between n the E EMS MS and the PC PCU. U. 3 Check that the the PCU is programmed programmed for the correct engine type.

 

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MID 128, PPID 267, Sea water  pressure D13, D16, D9

MID 128: Engine control unit FMI 1 – Data valid but below operational range Fault code explanation: Fault indication:

Seawater pressure too low •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

A red lamp lamp flash flashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

Engine performance is reduced.

Preconditions:

Seawater pressure too low

Conditions for fault code:

Seawater pressure is dependent on engine rpm. Seawater pressure is lower  than the value specified in the engine protection parameter. For parameters, refer to the engine protection folder.

Suitable action:

1 Check Check that that the the seawater seawater inta intake ke is not not block blocked. ed. 2 Check Check that that the the seawater seawater filt filter er is not not block blocked.. ed.. 3 Chec Check k th that at no no leaka leakage ge o occ ccur urs. s. 4 Check Check the the impell impeller er in the seaw seawate aterr pump.. pump.. 5 Check Check the sens sensor or by checki checking ng the seawa seawater ter pr press essure ure..

FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

Defective sensor/Defect in sensor circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Preconditions:

Voltage above normal or shorted high

Conditions for fault code:

Voltage on engine control unit pin A19 exceeds 4.95 volts.

Possible reason:

Suitable action:

•

Open Open circu circuit it in in th the e senso sensorr ne negati gative ve c cable able..

•

Short circuit circuit bet between ween the the sensor sensor signal cable and the the sensor sensor 5 V su supply pply cable or battery voltage.

•

Faul aulty sensor nsor..

1 Check the cable cable harness between between the sensor and th the e EMS 2. 2 Check contact contact pressure pressure in so socket cket 11 in engine connec connector tor A A.. 3 Chec Check k th the e sens sensor or..

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FMI 5 – Current below normal or open circuit Defective sensor/Defect in sensor circuit.

Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Preconditions:

 Abnormally low current or open circuit.

Conditions for fault code:

Voltage on engine control unit pin A19 lower than 0.07 volts.

Possible reason:

•

Open circui circuitt in the sensor sensor 5 V sup supply ply cable. cable.

•

Open Open circ circui uitt in sen senso sorr si sign gnal al c cab able le..

•

Short circuit circuit betw between een the the sen sensor sor signal signal cable cable and tthe he sen sensor sor n negativ egative e cable.

•

Faulty sensor.

1 Check the cable cable harness harness between the s sensor ensor and tthe he EM EMS S 2.

Suitable action:

2 Check contact contact pressure pressure in socket sockets s 7 and 19 in engine connec connector tor A. 3 Chec Check k th the e se sens nsor or..

a

Circuit description (-) 11

SB

(+ ) 7

b 1 4

R

  P2

19

GR P0007246

a

Connector A

b

Se Seaw awat ater er pr pres essu sure re sens sensor  or 

The sensor is of active type, i.e. it must be supplied with operating voltage. Pin 7 on engine control unit (EMS2) connector A supplies operating power of +5 volts to sensor pin 1. Sensor pin 4 is connected to battery negative via EMS2 pin 11. The seawater  pressure sensor output signal – sensor pin 2 to EMS2 pin 19 – is a voltage signal proportional to seawater  pressure.

 

Component specification Working range

0–300 kPa (0–3 bar)

Voltage Supply

5.00 ± 0.25 VDC

Nominal output voltage at 25 °C (77 °F) and supply voltage 5.00 VDC: 0.5 VDC at 0 kPa (0 bar) 4.5 VDC at 300 kPa (3 bar)

Measurements Checking negative cable, seawater pressure sensor, page 173 Checking supply cable, seawater pressure sensor, page 174 Checking signal cable, seawater pressure sensor, page 174 Checking the seawater pressure sensor, page 175 

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MID 128, SID 1/2/3/4/5/6 Injector # 1-6 MID 128: Engine control unit Fault code

Concerns

SID 1

Unit injector 1

SID 2

Unit injector 2

SID 3 SID 4

Unit injector 3 Unit injector 4

SID 5

Unit injector 5

SID 6

Unit injector 6

Volvo specific for injectors, FMI 3, 4, 5, 7, 12 FMI 3 – Short circuit to battery voltage, unit injector low voltage side Fault code explanation: Fault indication:

Symptom:

Preconditions: Conditions for fault code:

Fault in injection system. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

•

En Engi gine ne perfo perform rman ance ce is reduc reduced ed..

• The engine engine can run on on three three or or fi five ve cyli cylinde nders. rs. NOTICE! Identify the cylinder by using the SID number in the fault code. •

In Inje ject ctor or act actiiva vate ted d

•

Short circuit circuit to b battery attery voltage voltage on th the e pin on every every injector injector llow ow vol voltage tage side.* NOTICE! * NOTICE!  * Engine control unit: Pins 16, 24, 32, 48, 56.

Possible reason:

Suitable action:

•

Short Short circui circuitt betw between een high high voltag voltage e and low volt voltage age sides sides..

•

Short circuit circuit to battery voltage, voltage, lo low w vol voltage tage side, injection injection cable.

1 Check the cables cables between between the in injector jector and the engine contro controll unit unit..

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FMI 4 – Short circuit to battery negative, unit injector low voltage or high voltage side. Fault code explanation: Fault indication:

Symptom:

Preconditions: Conditions for fault code:

Fault in injection system. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

•

Engi Engine ne perfo perform rmanc ance e iis s red reduc uced ed..

•

The eng engine ine can can run run on thre three e or ffive ive cyl cylind inders. ers.

NOTICE! Identify the cylinder by using the SID number in the fault code. •

In Injjec ecto torr a act ctiv ivat ated ed

•

Short circuit circuit to battery voltage voltage on the pi pin n on every inject injector or lo low w vol voltage* tage* or high voltage side**. NOTICE! * NOTICE!  * Pins 16, 24, 32, 40, 48 and 56 on the engine control unit. ** Pins 59 and 60 on the engine control unit.

Possible reason: Suitable action:

Short circuit between the cables on every injector low voltage or high voltage side and battery negative. 1 Check the cables cables between between the in injector jector and the the engin engine e cont control rol unit. unit.

FMI 5 – Open circuit in the unit injector circuit Fault code explanation: Fault indication:

Symptom:

Preconditions: Conditions for fault code:

Possible reason:

Suitable action:

Fault in injection system. • Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y. •

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

•

Engi Engine ne perfo perform rmanc ance e iis s red reduc uced ed..

•

The eng engine ine can can run run on thre three e or ffive ive cyl cylind inders. ers.

NOTICE! Identify the cylinder by using the SID number in the fault code. •

In Injjec ecto torr a act ctiv ivat ated ed

•

Open Open circ circui uitt in the the inj injec ecto torr ci circ rcui uit. t.

•

Open circuit circuit in the the cables cables on on the low v voltage oltage or high high voltage voltage s side. ide.

•

If three three fault fault codes codes are are triggered triggered (a ban bank), k), tthe he open open cir circuit cuit is on that bank's high voltage side.

•

If only one fault fault code code is triggered, triggered, the open circuit circuit is on the injector' injector's s low voltage side.

1 Check the cables cables between between the in injector jector and the the engin engine e cont control rol unit. unit. 2 Check the the contact contact pressure pressure in all all soc sockets kets to unit unit inj injectors ectors in engine engine connector A.

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FMI 7 – Mechanical system not responding properly Fault code explanation: Fault indication:

Fault in injection system. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

Engine performance is reduced.

Preconditions:

NOTICE! Identify the cylinder by using the SID number in the fault code.

Conditions for fault code:

Possible reason:

•

In Inje ject ctor or act actiiva vate ted d

•

To Too o high high cyl cylin inder der bala balanc ncin ing g da data ta

•

Poor Poor co comp mpre ress ssiion on..

•

Fau aullt iin n inj injec ecto tor. r.

•

As Asym ymme metr tric ic eng engin ine e load load*. *.

* If the engine is asymmetrically loaded and a fault code is triggered it is not possible to remedy the fault code as there is no mechanical fault.  At idle the engine control unit will attempt to compensate for the uneven running by supplying more or less fuel to the injectors, so-called cylinder  balancing. If the asymmetric load is too great engine control unit compensation will be insufficient. The engine will run unevenly and a fault code will be triggered. Suitable action:

1 Do a compress compression ion test test and a cylinder cylinder balance balance test, using VODIA VODIA,, to localize the fault source. 2 Check the the injector injector by changing changing it. Th The e injectors injectors are manufac manufactured tured w with ith tolerance specifications. When an injector is changed an injector  trimming procedure must be carried out. The trim value is specified as a 6-character code on the injector's electrical connector. connecto r. The trim value is entered in VODIA only for the cylinder that has the replacement unit injector.

FMI 12 – Faulty device or component Fault code explanation: Fault indication:

Fault in injection system. •

Warnin Warning g is disp display layed ed in the tacho tachomet meter/ er/dis displa play. y.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

Engine performance is reduced.

Preconditions:

NOTICE! Identify the cylinder by using the SID number in the fault code.

Conditions for fault code:

Injector activated

Possible reason:

Intermittent fault

Suitable action:

1 Check the cables cables between between the in injector jector and the engine contro controll unit unit.. 2 Check the the contact contact pressure pressure in all sockets sockets to unit in injectors jectors in engi engine ne connector A. 3 Check Check the the cable cable connec connectio tion n to th the e inj inject ector. or.

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b

Circuit description

a

D9, D12, D16 The engine's unit injectors have electronically controlled solenoid valves. The solenoid valve is controlled by the engine control unit. The injectors receive voltage from pin 59 or 60 on the engine control unit. In order to activate a unit injector  solenoid valve the engine control unit connects the unit injector low side to battery negative. Each unit injector  is marked with a code on top of the electrical connection. If a unit injector is replaced the new code must be entered into VODIA for the cylinder  concerned.

P0007257

a

Connector A

b

Un Unit it inj injec ecto tor, r, c cyl ylin inde ders rs 1-6 1-6

  a Y 20 24 Y 59 Y Y 12 16 Y Y 62 Y 28 32 Y

D11, D13

b

Y 52 Y 56 Y 60 44 Y 48 Y 61 Y Y 36 Y 40

1

2 3

4

5

The unit injectors used on D11 and D13 engines have two electronically controlled solenoid valves. Each solenoid valve is individually controlled by the engine control unit. The unit injectors receive voltage from pin 59, 60, 61 or 62 on the engine control unit. In order to activate a unit injector solenoid valve the engine control unit connects the unit injector low side to battery negative. Each unit injector is marked with a code on top of the electrical connection. If a unit injector is replaced the new code must be entered into VODIA for the cylinder  concerned.

6

P0008674

a

Connector A

b

Un Unit it inj injec ecto tor, r, c cyl ylin inde ders rs 1-6 1-6

 

Measurements Injector trim, page 167  Checking the injector coils, page 168 

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MID 128, SID 21 Engine position FMI 2 – Data erratic, intermittent or incorrect Fault code explanation:

Faulty sensor / Faulty sensor circuit

Fault indication:

Yellow alarm status

Fault stored in memory:

Yes

Symptom:

None

Conditions for fault code:

Possible reason:

Suitable action:

•

Monito Monitoring ring cam cam speed speed sens sensor or vol voltag tage e wavefo waveform rm (clean (clean Vout signal without peaks and variations) and set fault when not according to specification

•

Faulty Faulty sy synch nchroni ronizat zation ion betwe between en camshaf camshaftt and cra cranks nkshaft haft

•

Incorrectly Incorrectly mounte mounted d sensor sensor (incor (incorrect rect distance distance b between etween sensor and toothed wheel, or loose sensor).

•

Intermittent Intermittent contact contact or electrical electrical interference interference on camshaft camshaft positi position on signal.

•

Faulty Faulty c corre orrelat lation ion betwe between en crank crank and c cam am signal signals, s, bad ti timin ming. g.

•

Polari Polarity ty fa fault ult,, the cables cables to the the senso sensorr are s shif hifted ted..

•

Faul aulty sensor nsor..

•

Dama Damage ged d ttoo ooth thed ed whee wheell

1 Check Check the the signal signal.. Use an os oscil cillos loscop cope. e. 2 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 3 Check that the the sensor sensor is correctly correctly in installe stalled d and tthat hat th the e dist distance ance between the toothed wheel and the sensor is correct. Refer to workshop manual (group 21–26). 4 Check contact contact pressure pressure in sockets sockets 45 and and 46 in in engine engine connector connector A. 5 Check the engine engine timing. timing. Refer to workshop workshop ma manual nual ((group group 2 21–26). 1–26). 6 Chec Check k th the e sens sensor or.. 7 Check Check that that the the toothe toothed d wheel wheel is not dama damaged ged..

FMI 3 – Voltage above normal or shorted high Fault code explanation:

Faulty sensor / Faulty sensor circuit

Fault indication:

Yellow alarm status

Fault stored in memory:

Yes

Symptom:

The engine start time will increase. Starting engine by using flywheel sensor.

Conditions for fault code:

No cam signal.

Possible reason:

Suitable action:

•

Open Open circu circuit it or or short short circ circuit uited ed s sens ensor or ca cable bles. s.

•

Faul aulty sensor nsor..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Check contact contact pressure pressure in sockets sockets 45 and and 46 in in engine engine connector connector A. 3 Chec Check k th the e sens sensor or..

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FMI 8 – Abnormal frequency, pulse width or period Fault code explanation:

Faulty sensor / Faulty sensor circuit

Fault indication:

Yellow alarm status

Fault stored in memory:

Yes

Symptom:

The engine start time will increase. Starting engine by using flywheel sensor.

Conditions for fault code:

Disturbances resulting in too many pulses. Monitoring cam speed sensor  voltage waveform (clean Vout signal without peaks and variations) and set

Possible reason:

Suitable action:

fault when not according to specification. • Incorrectly Incorrectly mounted sensor (incorr (incorrect ect distan distance ce b between etween sensor and toothed wheel, or loose sensor). •

Intermittent Intermittent contact or electri electrical cal interference interference on c camshaft amshaft positi position on signal.

•

Faulty se sensor 

1 Check Check the the signal signal.. Use an os oscil cillos loscop cope. e. 2 Check cables and connector connectors s betw between een the sensor and en engine gine control control unit. 3 Check that the the sensor sensor is correctly correctly in installe stalled d and tthat hat the distance distance between the toothed wheel and the sensor is correct. Refer to the workshop manual. 4 Check contact contact pressure pressure in socket sockets s 45 and and 46 iin n engine engine connector connector A A.. 5 Chec Check k th the e se sens nsor or..

D9, D12, D16

D11, D13

P0008694

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D11, D13, D16 Conn. A

D9, D12 Conn. A

Circuit description b

b

The camshaft sensor is an inductive sensor. The camshaft sensor is used in the first instance to determine which cylinder is next in line for injection. A reluctor wheel installed on the camshaft is used to determine which cylinder is next in line for injection. The reluctor wheel has 7 teeth, one for each cylinder  plus an extra tooth for cylinder 1. When theare camshaft and in reluctor wheelThe rotates, impulses generated the sensor. impulses generate a pulsed signal in the sensor which the engine control unit uses to determine which cylinder is next in line for injection.

Measurements P0007250

 

a

Connector A

b

Tach Tachom omet eter er sens sensor or (c (cam amsh shaf aft) t)

Checking camshaft sensor, page 163

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MID 128, SID 22 Timing sensor, crank MID 128: Engine control unit FMI 2 – Data erratic, intermittent or incorrect Fault code explanation:

Faulty sensor / Faulty sensor circuit

Fault indication: Fault stored in memory:

Yellow alarm status Yes

Symptom:

Conditions for fault code: Possible reason:

Suitable action:

•

Th The e engi engine ne star startt ti time me wil willl incr increas ease. e.

•

Engine is running running with imprecise imprecise ttiming iming causing causing risk risk of high fuel consumption and smoke.

•

Cylind Cylinder er balanci balancing ng not worki working ng wit with h risk o off unev uneven en runnin running. g.

Monitoring crank speed sensor voltage waveform (clean Vout signal without peaks and variations) and set fault when not according to specification. •

Incorrectly Incorrectly mounted sensor (incorr (incorrect ect distan distance ce b between etween sensor and flywheel, or loose sensor).

•

Intermittent Intermittent contact contact or electrical electrical interference interference on c cranksha rankshaft ft p positio osition n signal.

• •

Polari Polarity ty fa fault ult,, the cabl cables es to the sens sensor or ar are e shi shifted fted.. Faulty sensor.

•

Dama Damage ged d fl flyw ywhe heel el

1 Check Check the the signal. signal. Use an os oscil cillos loscop cope. e. 2 Check cables and connector connectors s betw between een the sensor and en engine gine control control unit. 3 Check that the the sensor sensor is correctly correctly ins installed talled and that that the distan distance ce between the flywheel and the sensor is correct. Refer to the workshop manual. 4 Check contact contact pressure pressure in socket sockets s 37 and and 38 iin n engine engine conn connector ector A A.. 5 Chec Check k th the e se sens nsor or.. 6 Check Check that that the the flyw flywhee heell is not damaged damaged..

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FMI 3 – Voltage above normal or shorted high Fault code explanation:

Faulty sensor / Faulty sensor circuit

Fault indication:

Yellow alarm status

Fault stored in memory:

Yes

Symptom:

Conditions for fault code: Possible reason:

Suitable action:

•

Th The e engin engine e star startt ti time me wil willl incr increa ease se..

•

Engine is running running with impreci imprecise se ti timing ming causing causing risk of high high fu fuel el consumption and smoke.

•

Cylinde Cylinderr balanci balancing ng not w worki orking ng wit with h risk o off unev uneven en runnin running. g.

No crank signal. •

Open Open circu circuit it or or short short circ circuit uited ed s sens ensor or ca cable bles. s.

•

Faul ultty sensor nsor..

1 Check cables and connector connectors s between between the sensor and eng engine ine co control ntrol unit. 2 Check contact contact pressure pressure in sockets sockets 37 and and 38 in in engine engine connector connector A. 3 Chec Check k th the e sens sensor or..

133

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FMI 8 – Abnormal frequency, pulse width or period Fault code explanation:

Faulty sensor / Faulty sensor circuit

Fault indication:

Yellow alarm status

Fault stored in memory:

Yes

Symptom:

Conditions for fault code:

Possible reason:

Suitable action:

•

Th The e engi engine ne star startt ti time me wil willl incr increas ease. e.

•

Engine is running running with imprecise imprecise ttiming iming causing causing risk risk of high fuel consumption and smoke.

•

Cylind Cylinder er balanci balancing ng not worki working ng wit with h risk o off unev uneven en runnin running. g.

Disturbances resulting in too many pulses. Monitoring crank speed sensor  voltage waveform (clean Vout signal without peaks and variations) and set fault when not according to specification. •

Incorrectly Incorrectly mounted sensor (incorr (incorrect ect distan distance ce b between etween sensor and flywheel, or loose sensor).

•

Intermittent Intermittent contact or electri electrical cal interference interference on c cranksha rankshaft ft p positio osition n signal.

•

Faulty se sensor 

1 Check Check the the signal signal.. Use an os oscil cillos loscop cope. e. 2 Check cables and connector connectors s betw between een the sensor and en engine gine control control unit. 3 Check that the the sensor sensor is correctly correctly in installe stalled d and tthat hat the distance distance between the toothed wheel and the sensor is correct. Refer to the workshop manual. 4 Check contact contact pressure pressure in socket sockets s 37 and and 38 iin n engine engine connector connector A A.. 5 Chec Check k th the e se sens nsor or..

D9, D12, D16

D11, D13

P0008694

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D11, D13, D16 a

Circuit description b

VO (D13)

D9, D12

a b

The flywheel sensor is an inductive sensor. The flywheel sensor is used for monitoring engine rpm It is also used to measure cylinder acceleration. The flywheel has 3 x 18 depressions per revolution. These depressions are detected by the flywheel sensor which generates a pulsed signal. The engine control unit uses the pulsed signal to determine flywheel rpm. Two cylinders each share one flywheel depression sector (cylinders 1 and 6, 2 and 5, 3 and 4). 4) . This means that it is not possible to know which cylinder is in line for injection, without the camshaft sensor.

P0016316

a

Connector A

b

Tach Tachom omet eter er sens sensor or (f (fly lywh whee eel) l)

 

Measurements Checking flywheel sensor, page 160 

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MID 128, SID 32, Wastegate output driver  D12, D13

MID 128: Engine control unit FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

Fault in wastegate valve or fault in circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

Engine power is reduced.

Preconditions:

Voltage above normal or shorted high

Conditions for fault code:

Excessive voltage on engine control unit pin B 38.

Possible reason:

Suitable action:

•

Short Short circui circuited ted contr control ol valve valve sig signal nal to b batte attery ry positi positive. ve.

•

Fa Faul ultt iin n the the wast wasteg egate ate valv valve. e.

1 Check cables and connector connectors s betw between een the control unit and and the control control valve. 2 Chec Check k th the e wast wastega egate te val valve ve..

FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation: Fault indication:

Fault in wastegate valve or fault in circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

Engine power is reduced.

Preconditions:

Voltage below normal or shorted to lower voltage

Conditions for fault code:

Voltage too low on engine control unit pin B 38.

Possible reason:

Suitable action:

•

Short Short circui circuited ted contr control ol valve valve sig signal nal to b batte attery ry negati negative. ve.

•

Fa Faul ultt iin n the the wast wasteg egate ate valv valve. e.

1 Check cables and connector connectors s betw between een the control unit and and the control control valve. 2 Chec Check k th the e wast wastega egate te val valve ve..

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FMI 5 – Current below normal or open circuit Fault in wastegate valve or fault in circuit.

Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

Engine power is reduced.

Preconditions:

 Abnormally low current or open circuit.

Conditions for fault code:

Wrong voltage on engine control unit pin B 38.

Possible reason:

•

Open Open cir circu cuit it iin n contr control ol val valve ve s sig ignal nal..

•

Fa Faul ultt iin n the the wast wasteg egat ate e val valve ve..

1 Check cables and connector connectors s between between the control control unit and the control valve.

Suitable action:

2 Check contact contact pressure pressure in so socket cket 38 in engine connec connector tor B B.. 3 Chec Check k th the e wast wasteg egat ate e valv valve. e.

Circuit description D12, D13 single turbo

D12, D13 single turbo (not classified) b

a

(+) 57 R / BL R / BL (+) 60 38

The engine is equipped with a turbocharger with waste gate valve. The valve is located beneath the

2 1

D12: GN D13: GN / OR

protective cover for the relays. The wastegate valve controls the amount of exhaust flow that passes through the exhaust turbine. Air pressure measured in the inlet manifold is used to determine how far the wastegate valve will be opened.

EMS2

 An electronically governed control valve is used by the engine control unit to control the level of air pressure supplied to the wastegate valve. When air pressure supplied to the wastegate valve by the control valve increases, the valve opens more. When the wastegate valve is fully open, exhaust gas flow to the exhaust turbine is at its lowest.

P0016318

a

Waste astega gate te Valv Valve e

b

Connector B

D13CC single turbo a

The control valve is controlled by current from the engine control unit with the aid of a PWM signal. The

+15

58 BL/R 2

EMS2 b 38

PM

GN/OR

P0017178 P0017178

a

Connector A

b

Connector B

c

Waste astega gate te Valv Valve e

c

1

greater the the inlet current supplied to the control valve, the greater pressure increase. Inlet pressure is constantly monitored by a sensor installed in the inlet manifold.

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D13 twin turbo The engine is equipped with two turbochargers with a wastegate valve. The wastegate valve controls the amount of exhaust gas flow that passes through the exhaust turbine. Oil pressure is used to control the amount that the wastegate opens. The wastegate valve is controlled by the EMS. The EMS uses a pulse width modulated signal to control the wastegate valve.

P0010641

 

P0010639

 

Measurements Checking the wastegate valve, page 159

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MID 128, SID 89 Air Compressor  Actuator Circuit D11

MID 128: Engine control unit FMI 3 – Voltage above normal or shorted high Fault code explanation:

Faulty supercharger circuit

Fault indication:

 An orange lamp flashes in the alarm display.

Symptom:

The engine gives less power, which results in less performance during acceleration and when heavily loaded.

Conditions for fault code:

The voltage at EECU pin B 2 is higher than normal.

Possible reason:

Suitable action:

•

Short Short circui circuited ted so solen lenoid oid suppl supply y cabl cable e to bat battery tery volt voltage age..

•

Short Short circui circuitt in sol soleno enoid id negati negative ve cable cable or su suppl pply y cabl cable. e.

•

Faulty cl clutch

1 Check cables and connector connectors s between between the control control unit and the supercharger. 2 Magn Magnet etic ic clu clutc tch h

FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation:

Faulty supercharger circuit

Fault indication:

 An orange lamp flashes in the alarm panel.

Symptom:

The engine gives less power, which results in less performance during acceleration and when heavily loaded.

Conditions for fault code:

The voltage at EECU pin B 2 is lower than normal.

Possible reason:

Suitable action:

•

Short circuited circuited solenoid solenoid power power s supply upply cable to b battery attery negati negative. ve.

•

Faulty cl clutch

1 Check cables and connector connectors s between between the control control unit and the supercharger. 2 Magn Magnet etic ic clu clutc tch h

FMI 5 – Current below normal or open circuit Fault code explanation:

Faulty supercharger circuit

Fault indication:

 An orange lamp flashes in the alarm panel.

Symptom:

The engine gives less power, which results in less performance during acceleration and when heavily loaded.

Conditions for fault code:

Incorrect voltage in the engine control unit, pin B 2.

Possible reason:

Suitable action:

•

Open Open cir circu cuit it iin n contr control ol val valve ve s sig ignal nal..

•

Fa Faul ulty ty wast wasteg egat ate e val valve ve

1 Check cables and connector connectors s between between the control control unit and the control valve. 2 Check the contact contact pressur pressure e in s socket ocket 38 in tthe he engine engine con connector nector B.

3 Chec Check k th the e wast wasteg egat ate e valv valve. e.

140

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Circuit description  An electromagnetic clutch is used to engage and disengage the mechanical supercharger. The EECU activates the coupling by providing the coupling solenoid with voltage from pin B2. Pin 2 from the coupling is connected to battery negative.

P0010642

 

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MID 128, SID 232 5 V supply MID 128: Engine control unit FMI 3 – Voltage above normal or shorted high Fault code explanation: Fault indication:

Fault in sensor supply circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An orange orange lamp lamp flashes flashes in the alarm panel or som some e dis display play values show - - -.

Symptom:

None

Conditions for fault code:

Voltage above normal or shorted high

Possible reason:

Short circuit to battery voltage on the output.

Suitable action:

1 Check the the supply supply voltage voltage to th the e sensors sensors whic which h have set set the fault fault codes. codes. 2 Chec Check k the the sens sensor or cabl cables es..

FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation: Fault indication:

Fault in sensor supply circuit. •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An orange orange lamp lamp flashes flashes in the alarm panel or som some e dis display play values show - - -.

Symptom:

None

Conditions for fault code:

Voltage below normal or shorted to lower voltage

Possible reason:

Suitable action:

•

Coolant Coolant temperature temperature sensor, sensor, sen sensor sor s signal ignal cable short circui circuitt to 5 V power.

•

Oil pressur pressure e sens sensor, or, sensor sensor signal cable short circui circuitt to 5 V power.

•

Charge air pressur pressure e sens sensor, or, s sensor ensor signal cable short circui circuitt to 5 V power.

•

Fuel pressure pressure sensor, sensor, sensor sensor signal cable short circui circuitt to 5 V power.

•

Coolant Coolant pressure pressure sensor, sensor, sensor signal cable short circuit circuit to 5 V power. power.

•

Crankcase Crankcase pressure pressure sensor, sensor, sens sensor or si signal gnal cable short circu circuit it to 5 V power.

•

Seawater Seawater pressure pressure sensor, sensor, sens sensor or sig signal nal cable cable short circui circuitt to 5 V power.

•

Short Short circu circuite ited d power power cable cable to to bat battery tery negati negative. ve.

•

Short Short circu circuite ited d signal signal cabl cable e to ba batte ttery ry ne negat gative ive..

1 Check the supply supply voltage voltage to the above-me above-mentione ntioned d sensors. sensors. 2 Chec Check k the the sens sensor or cabl cables es..

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MID 128, SID 240 Program memory MID 128: Engine control unit FMI 2 – Data erratic, intermittent or incorrect Fault code explanation: Fault indication:

Communication fault •

Warnin Warning g is displ displaye ayed d in th the e tachom tachometer eter/di /displ splay. ay.

Symptom:

• An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m displ display. ay. None

Conditions for fault code:

Software checksum error 

Possible reason:

Failed download

Suitable action:

1 Tr Try y to rel reload oad th the e soft softwa ware re.. 2 Try Try an anot othe herr EECU EECU..

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MID 128, SID 254 Controller 1 MID 128: Engine control unit FMI 3 – Voltage above normal or shorted high FMI 12 – Faulty device or component Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tacho tachomet meter/ er/dis displa play. y.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Conditions for fault code:

Internal fault in engine control unit

Suitable action:

 

Defective component.

1 Chan Change ge the engi engine ne ECU. ECU.

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MID 128, SID 231 SAE J1939 data link MID 128: Engine control unit FMI 2 – Data erratic, intermittent or incorrect Communication fault J1939

Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Conditions for fault code:

Data bus, CAN, communication not found.

Possible reason:

•

CAN H short short ci circui rcuited ted tto o battery battery negati negative ve on pin 3. 3.

•

Conductors Conductors in in con control trol link CAN H and CAN L shor shortt cir circuited cuited to ea each ch other.

•

CAN L short short circ circuit uited ed tto o supply supply voltage voltage on p pin in 4 4..

1 Check the data data bus cables and terminals terminals between between the e engine ngine control unit and PCU. Refer to ”Functional disruptions, checking bus cables”.

Suitable action:

FMI 9 – Abnormal update rate Communication fault J1939

Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

An orang orange e la lamp mp flas flashes hes in tthe he alar alarm m di displ splay. ay.

Symptom:

None

Conditions for fault code:

 Abnormal update rate 1 Check the data data bus cables and terminals terminals between between the e engine ngine control unit and PCU. Refer to ”Functional disruptions, checking bus cables”.

Suitable action:

Circuit description A B C D E F G H

a

P0007123

 

a

PCU conn onnecto ectorr X X3 3 Color: Pink

b

Engi ngine c con onne nec cto tor  r  “BUS INTERFACE”

b

A B C D H F G E

 A CAN H – Data link to engine B CAN L – D Data ata llink ink tto o engine engine C Inp Input ut volt voltage, age, 0 V D Inp Input ut volt voltage, age, 24 V E J17 J1708B 08B – D Data ata link link tto o engine engine F Not us used G J1708A – Data link tto o engine engine H Ign Igniti ition on signal signal

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MID 128, PSID 112 Exhaust Manifold Water Temperature Sensor #1 MID 128: Engine control unit FMI 0 – Data valid but above normal operational range Fault code explanation:

Excessive exhaust manifold water temperature

Fault indication: Fault stored in memory:

Yellow alarm status Yes

Symptom:

 At poor sea water flow the exhaust manifold water temperature rises.

Conditions for fault code:

Exhaust manifold water temperature exceeds the set value of the engine protection parameter. Refer to Administra to Administration, tion, page 9 9..

Possible reason:

Suitable action:

•

Crushe Crushed/l d/leak eaking ing/bl /block ocked ed hose on the the sucti suction on side (seaw (seawate ater) r)

•

Worn Worn im impe pell ller er in seaw seawat ater er pum pump p

•

Po Poor or flo flow w thro through ugh the the sea sea wat water er sy syst stem em

•

Faulty se sensor 

1 Check the sea sea water water system system for leakage leakage and ffor or sque squeezed ezed hoses. hoses. 2 Check Check the the impell impeller er in the sea sea wa water ter p pump. ump. 3 Check Check the the flow flow in the the sea sea w water ater sys system tem.. 4 Check the exhaust exhaust manifold manifold water temperature temperature sensor sensor..

FMI 3 – Voltage above normal or short circuit to higher voltage Fault code explanation:

Faulty sensor / Fault in sensor circuit.

Fault indication:

Yellow alarm status

Fault stored in memory:

Yes

Symptom:

None

Conditions for fault code:

Voltage on pin 43 on engine ECU is too high.

Possible reason:

Suitable action:

•

Short Short circu circuite ited d sensor sensor 5 V suppl supply y cab cable le to b batt attery ery v volt oltage. age.

•

Short circuited circuited s sensor ensor signal cable to ba battery ttery voltage voltage or 5 V voltage. voltage.

• Faulty se sensor  1 Check all cables cables a and nd connectors connectors betwee between n the s sensor ensor and and the engine ECU. 2 Chec Check k th the e sens sensor or..

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FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation:

Faulty sensor / Fault in sensor circuit.

Fault indication:

Yellow alarm status

Fault stored in memory:

Yes

Symptom:

None

Conditions for fault code:

Voltage on pin 43 on engine ECU is too low.

Possible reason:

Suitable action:

•

Short Short circui circuited ted senso sensorr sign signal al cable cable to bat batter tery y nega negativ tive. e.

•

Faulty se sensor 

1 Check all cables cables a and nd connectors connectors between between the s sensor ensor and the engine ECU. 2 Chec Check k th the e se sens nsor or..

FMI 5 – Current below normal or open circuit Fault code explanation:

Faulty sensor / Fault in sensor circuit.

Fault indication:

Yellow alarm status

Fault stored in memory:

Yes

Symptom:

None

Conditions for fault code:

Voltage on pin 43 on engine ECU is too high.

Possible reason:

Suitable action:

•

Open Open circ circui uitt in sen senso sorr si sign gnal al c cab able le..

•

Open circui circuitt in sensor sensor battery battery negati negative ve c cabl able. e.

•

Faulty se sensor 

1 Check all cables cables a and nd connectors connectors between between the s sensor ensor and the engine ECU. 2 Chec Check k th the e se sens nsor or..

Circuit description The exhaust manifold water temperature sensor is a Pt-200 sensor which means that the resistance output from the sensor is 200 ohm at 0 °C (32 °F). The resistance will rise with the temperature. Sensor Pin 1 Pin 2

Engine ECU B18 B43

Signal type batTemp input

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MID 128, PSID 216 Data Link, MID187 MID 128: Engine control unit FMI 9 – Abnormal update rate Communication fault J1939

Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

An oran orange ge llamp amp fla flashe shes s in the alarm alarm d disp isplay lay..

Symptom:

None

Conditions for fault code:

 Abnormal updating rate on the J1939 data bus between the EMS and the PCU

Possible reason:

•

AUX AUX sto stop p but button ton is acti activa vate ted. d.

•

Open Open circ circui uitt iin n CAN CAN L or or CAN CAN H.

•

One or or two conductors conductors in CAN CAN short short ci circuite rcuited d to battery negative, negative, pin pin 3.

•

Conductors Conductors in in cont control rol link link CAN CAN H and CA CAN N L short circu circuited ited to to eac each h other.

•

CAN H short short circui circuited ted to the the power power supp supply, ly, pin 4.

•

CAN short short circ circuit uited ed tto o ”igni ”ignitio tion n si signa gnal”. l”.

•

Int Intermi ermitte ttent nt cont contact act in power power sup supply ply to data data bus bus

•

Open circuit circuit in the power power supply cable betwee between n the engine control unit and the PCU.

1 Check Check that that the the AUX stop stop butto button n is no nott acti activate vated. d.

Suitable action:

2 Check the databus databus cables cables and the the conne connections ctions between between the e engine ngine control unit and the PCU. Refer to ”Functional disruptions, checking bus cables”. 3 Check the power power supply supply cable cable between between the engine control unit an and d the PCU. 4 Check contact contact pressure pressure in sockets sockets 51 and and 55 in in engine engine connector connector B.

Circuit description A B C D E F G H

a

P0007123

 

a

PCU co conn nnec ecto torr X3 X3 Color: Pink

b

Engin ngine e conn conne ector  ctor  “BUS INTERFACE”

b

A B C D H F G E

 A CAN H – Data link to engine B CAN L – D Data ata llink ink tto o engine engine C Inp Input ut volt voltage age,, 0 V D Inp Input ut volt voltage age,, 24 V E J1708B – Dat Data a lilink nk to engine F Not u us sed G J1708A – Data llink ink to engine engine H Ign Igniti ition on signal signal

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MID 158, PSID 1, Primary battery circuit MID 158: Power module FMI 3 – Voltage above normal or shorted high FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation:

Poor batteries or charging

1 A warnin warning g is shown shown in in the tacho tachomet meter/d er/disp isplay lay..

Fault indication:

2  At low charging: Battery indicator lamp flashing in alarm panel. 3 A red lamp lamp fla flashes shes in in the alarm d display isplay + audible audible w warning arning.. None

Symptom: Conditions for fault code:

•

FMI 3: Voltage exceeds 29 V (old power module(1)) or 32 V (newer  power module) for more than 30 seconds.

•

FMI 4: Voltage is less than 24,3 V (old power module(1)) or 23,6 V (newer power module) for more than 30 seconds.

Poor batteries or charging

Preconditions:

General checking 1 Check Check the the batte battery ry elec electrol trolyte yte level level.. 2 Check Check the the density density in in all of the the batter batteries ies'' cel cells. ls. Possible reason:

•

Batt Batter ery y vol volta tage ge to too o low low

•

Poor c ch harging

1 Check that the the cable cable harness harness bet between ween tthe he batt battery ery an and d the p power  ower  module is undamaged.

Suitable action:

2 Check Check the batter batteries ies condit condition ion.. 3 Check Check that the alterna alternator tor cha charges rges..

e

Circuit description

PM 11529 6 7 78 8 14 28 42 R R

d

SB

c

a

c

SB

b

P0017212

 

a

Pri rima mary ry Bat atttery ery

b

Seco Second ndar ary y Batt Batter ery y

c

Ma Main in ba batt tter ery y swit switch ch

d

St Star arte terr mo moto torr / junc juncti tion on b box ox

e

Power Module

 As soon as the power module receives power from the primary battery or the secondary battery, with main battery switches on, the 30 supply output is powered (connected to key switch and MCC / EVC). If the power  module receives a +15 ignition signal it will activate EMS2 and extra power outputs (engine mounted instruments such as EasyLink, External stop and Water in fuel). The power module internal relay function switches between primary battery and secondary battery depending on highest voltage. The two battery groups are never active at the same time. The power module monitors the battery voltage level and if it is too low/ high >30 seconds FMI 3/4 is set.

1. Part no. 3809645, 21114790, 21312264 and 21350893.

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MID 158, PSID 2, Secondary battery circuit MID 158: Power module FMI 3 – Voltage above normal or shorted high FMI 4 – Voltage below normal or shorted to lower voltage Fault code explanation:

Poor batteries or charging

1 Warnin Warning g is display displayed ed in the tac tachom homete eter/di r/displ splay. ay.

Fault indication:

2  At low charging: Battery indicator lamp flashing in alarm panel. 3 A red lamp flashes flashes in in the alarm alarm display display + audi audible ble wa warning. rning. None

Symptom: Conditions for fault code:

•

FMI 3: Voltage exceeds 29 V (old power module(1)) or 32 V (newer  power module) for more than 30 seconds.

•

FMI 4: Voltage is less than 24,3 V (old power module(1)) or 23,6 V (newer power module) for more than 30 seconds.

Poor batteries or charging

Preconditions:

General checking 1 Check Check the the batte battery ry elec electro trolyt lyte e level level.. 2 Check Check the dens density ity in all all of the batt batteri eries' es' cells cells.. Possible reason:

•

Ba Batt tter ery y vol volta tage ge to too o low low

•

Poor c ch harging

1 Check that the the cable cable harness harness bet between ween tthe he bat battery tery an and d the p power  ower  module is undamaged.

Suitable action:

2 Check Check the batteri batteries es condit condition ion.. 3 Check Check that that the altern alternato atorr charg charges. es.

e

Circuit description

PM 11529 6 7 8 14 28 42 R R SB

a

c

SB

b

P0017212

 

a

Prim rimar ary y Batt Batter ery y

b

Seco Second ndar ary y Ba Batt tter ery y

c

Ma Main in ba batt tter ery y swit switch ch

d

St Star arte terr moto motorr / jun junct ctio ion n box box

e

Power Module

 As soon as the power module receives power from the primary battery or the secondary battery, with main battery switches on, the 30 supply output is powered (connected to key switch and MCC / EVC). If the power  module receives a +15 ignition signal it will activate EMS2 and extra power outputs (engine mounted instruments such as EasyLink, External stop and Water in fuel). The power module internal relay function switches between primary battery and secondary battery depending on highest voltage. The two battery groups are never active at the same time. The power module monitors the battery voltage level and if it is too low/ high >30 seconds FMI 3/4 is set.

1. Part no. 3809645, 21114790, 21312264 and 21350893.

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MID 158, PSID 4, 30 supply fuse MID 158: Power module FMI 6 – Current above normal or short circuit to battery negative Too high current output

Fault code explanation: Fault indication:

•

Warnin Warning g is disp display layed ed in the tach tachome ometer/ ter/dis displa play. y.

•

A red lamp lamp fl flash ashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

None

Conditions for fault code:

Excessive power supply. (Power supply to other systems, pin 4 in the 8-pole engine connector).

Possible reason:

•

Shor Shortt c circ ircui uitt iin n tthe he syst system em..

•

Too high load

1 Check for short short circuits circuits in in the cable cable ha harness rness from th the e suppl supply y module module to the 8-pole engine connector.

Suitable action:

2 Reduce uce lloa oad d.

Circuit description EVC HCU

MCC

PCU

b

5 4 3

R/BL R a

EMS2  A58

10 11 2 3

PM

P0017216

 

a

Power Module

b

8-po 8-pole le c co onne nnecto ctor 

 As soon as the power module receives power from the primary battery or the secondary battery, with main battery switches on, the 30 supply output is powered (connected to key switch and MCC / EVC). If the power  module receives a +15 ignition signal it will activate EMS2 and extra power outputs (engine mounted instruments such as EasyLink, External stop and Water in fuel). The power module internal relay function switches between primary battery and secondary battery depending on highest voltage. The two battery groups are never active at the same time. The power module monitors the battery voltage level.

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MID 158, PSID 5, EMS supply fuse MID 158: Power module FMI 5 – Current below normal or open circuit Fault code explanation:

Fault indication:

Symptom:

Conditions for fault code: Possible reason:

Suitable action:

Open circuit in wires to emergency stop / shutdown relay / EMS2 during start up of power module. • •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay. A red lamp lamp flash flashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

•

Warnin Warning g is remov removed ed only only after after new new s start tartup up se sequen quence. ce.

•

Receiving Receiving warnings warnings but but fully fully functional functional (if o one ne wire wire is broken). broken). Redundant wiring.

•

No power power to to EMS, EMS, not able to to start start en engine gine (if (if tw two o wires wires ar are e broken). broken).

Open circuit in at least one of the supply voltage wires to the EMS2. •

Emerge Emergency ncy st stop op but button ton may may be acti activat vated ed dur during ing po power wer up (butt (button on locked in depressed position).

•

Open Open circui circuitt in one o off the cabl cables es to th the e emergen emergency cy st stop op bu button tton..

•

Open circuit circuit in one or two wires wires from e emergenc mergency y sto stop p button button to EMS.

1 Reset the emergency emergency stop button button ((pull pull the the button button up u until ntil a click is heard). Reset system with main switches for primary and secondary batteries. 2 Check that the the EMS2 EMS2 has supply voltage voltage on bo both th pin B57 and and B60. 3 Check the emergenc emergency y stop stop button button in internal ternal switch switches es / wiring wiring.. 4 This fault fault code code might be wrongly wrongly set iiff power module module iis s of olde olderr model (part no. 3812846, 3809645, 21114790, 21312264 or 21350893). Change power module.

FMI 6 – Current above normal or short circuit to battery negative Fault code explanation: Fault indication:

Faulty supply voltage to the engine control unit •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

A red lamp lamp flash flashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

Engine stops or cannot be started.

Preconditions:

Faulty supply voltage to the engine control unit

Conditions for fault code:

Too high current output

Possible reason:

Suitable action:

•

Sh Shor ortt c cir ircu cuit it in th the es sys yste tem. m.

•

Too high load

1 Check the cable cable harness harness from from the power module for sh short ort ci circuit. rcuit. 2 Reduce lo load.

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(D13) BL/R

5

2 c

1 2

3 4 b

57 60 EMS2 (B) P0017218

 

a

Power Module

b

Eme merg rge ency ncy Sto Stop

c

Sh Shut utdo down wn re rela lay y ((on only ly D1 D13) 3)

Circuit description

BL/R BL/R a 13 12

PM

 As soon as the power module receives power from the primary battery or the secondary battery, with main battery switches on, the 30 supply output is powered (connected to key switch and MCC / EVC). If the power  module receives a +15 ignition signal it will activate EMS2 and extra power outputs (engine mounted instruments such as EasyLink, External stop and Water in fuel). The power module internal relay function switches between primary battery and secondary battery depending on highest voltage. The two battery groups are never active at the same time. The power module monitors the battery voltage level.

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MID 158, PSID 6, Extra supply fuse MID 158: Power module FMI 6 – Current above normal or short circuit to battery negative Fault code explanation: Fault indication:

Too high current output •

Warnin Warning g is disp display layed ed in the tach tachome ometer ter/di /displ splay. ay.

•

A red lamp lamp flash flashes es in the the alarm alarm di displ splay ay + au audib dible le wa warni rning. ng.

Symptom:

None

Preconditions:

Faulty supply voltage to the engine control unit

Conditions for fault code:

Excessive power in the 24 V supply from the power module. - Water monitor, fuel filter  - ”Easy Link” - External stop

Possible reason:

•

Short Short circ circuit uit on pin pin 4 and and pin pin 5 on pow power er m modul odule. e.

•

Too high high load load Contin Continuous uously ly more than than 7A. 7A.

1 Check the cable cable harness harness from from the power module for sh short ort ci circuit. rcuit.

Suitable action:

2 Reduce lo load.

Circuit description BL/R

4

1

b

2 c

1

5

PM

a

GN

 A27

EMS2

P0017253

 

a

Power Module

b

Easy Easy Link Link conn connec ecto tor  r 

c

External stop

 As soon as the power module receives power from the primary battery or the secondary battery, with main battery switches on, the 30 supply output is powered (connected to key switch and MCC / EVC). If the power  module receives a +15 ignition signal it will activate EMS2 and extra power outputs (engine mounted instruments such as EasyLink, External stop and Water in fuel). The power module internal relay function switches between primary battery and secondary battery depending on highest voltage. The two battery groups are never active at the same time. The power module monitors the battery voltage level.

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Measurements Checking supply cable, coolant pressure sensor  Tools: 88890074 Multimeter  9998534 Break-out cable 885675 Break-out cable 1 NOTICE! Turn NOTICE! Turn off ignition. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. 4 Tu Turn rn on igni igniti tion on.. Measurement points

Nominal value

1-4

U≈5V

 

Checking negative cable, coolant pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Dis Discon connec nectt the c conn onnect ector or fr from om the the sen sensor  sor  3 cable Con Connect nect b brea reak-o k-out ut cable cable 99 99985 or 88 88567 5675 5 to the harness connector to 98534 the 34 engine contro control l unit. 4 Use mult multime imeter ter 8 8889 8890074 0074 to do rresi esista stance nce measurement towards the engine control unit.

4

Measurement points

Nominal value

4 - Battery negative

R≈0Ω

9998534 P0007186

 

NOTICE! Battery negative (–) on alternator or starter  NOTICE! Battery motor.

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Checking signal cable, coolant pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Discon Disconnec nectt the connect connector or fr from om th the e sen sensor  sor  3 Connec Connectt brea break-o k-out ut cable cable 99985 9998534 34 or 88 88567 5675 5 to the cable harness connector to the engine control unit. un it. 4 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit.

 

Measurement points

Nominal value

2-4

R ≈ 80 - 120 kΩ

NOTICE! Measurement is done to eliminate short NOTICE! Measurement circuiting or breaks in the cable to the engine control unit.

Checking the coolant pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 Tu Turn rn off off iign gnit itio ion. n. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the connect connector or fr from om th the e sen sensor  sor  3 Connec Connectt bre breakak-out out cabl cable e 999 999853 8534 4 or 88 885675 5675 between the sensor and engine control unit. 4 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. 5 Tu Turn rn on igni igniti tion on.. Measurement points

Nominal value

2-4

U ≈ 0,5 V

Component specification Working range 0–300 kPa (0–3 bar) Power supply 5,00 ± 0,25 VDC Nominal output voltage at 25 °C (77 °F) and supply voltage 5.00 VDC: 0,5 VDC at 4,5 VDC at

0 kPa (0 bar) 300 kPa (3 bar)

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Checking supply cable, fuel pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Dis Discon connec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Turn Turn the the start starter er key key to to po posit sition ion 1. 4 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. Measurement points

Nominal value

1-4

U≈5V

 

Checking negative cable, fuel pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 Cut the curr current ent w with ith the main main swi switch. tch. 2 Dis Discon connec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 8890074 0074 to do resi resista stance nce measurement towards the engine control unit. 4 Measurement points

Nominal value

4 - Battery negative*

R≈0Ω

9998534 P0007190

 

NOTICE! Battery negative (–) on alternator or starter  NOTICE! Battery motor.

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Checking signal cable, fuel pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit. Measurement points

Nominal value

2 - Battery negative*

R ≈ 80 - 120 kΩ

NOTICE! Measurement is done to eliminate short NOTICE! Measurement circuiting or breaks in the cable to the engine control unit.

 

NOTICE! Battery negative (–) on alternator or starter  NOTICE! Battery motor.

Checking the fuel pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Disconn Disconnect ect th the e connect connector or fro from m the senso sensorr Conn Connect ect break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Turn Turn the the starte starterr ke key y to pos positi ition on 1. 1. 4 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. Measurement points

Nominal value

2-4

U ≈ 0,5 V

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Checking the wastegate valve Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 

1 NOTICE! Cut NOTICE! Cut the current with the main switch. 2 Remove Remove th the e connec connector tor fr from om the the was wastega tegate te valve valve.. Connect break-out cable 9998534 or 885675 to the valve. Do not connect the other end of the adapter  cable. 3 Use mult multime imeter ter 8 8889 8890074 0074 to do rresi esista stance nce measurements. NOTICE! Measurement is done to eliminate short NOTICE! Measurement circuiting or breaks in the wastegate valve.

885 675 P0008932

 

Measurement points

Nominal value

1–2

R = 90 ± 4.5 Ω at 20 °C (68 °F)

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Checking flywheel sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE!  Cut the current with the main switch. NOTICE! Cut 2 Remove Remove the the co conne nnecto ctorr fro from m the sens sensor or an and d remo remove ve the sensor from the flywheel housing. Check that the sensor has no external damage or  swarf adhering to it.

1

3 Connec Connectt brea break-o k-out ut cable cable 99985 9998534 34 or 88 88567 5675 5 to th the e sensor. Do not connect the other end of the adapter  cable. 4 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurements.

2 P0007251

 

Measurement points

Nominal value

1–2

R ≈ 0.9 kΩ*

NOTICE! * NOTICE!  * ±10% at 20 °C (68 °F). 5 Use multi multimet meter er 981251 9812519 9 for vol voltag tage e measure measurement ment.. Move a metal object rapidly back and forth at a distance of no more than 1 mm (0.039") in front of  the sensor. Check that the multimeter gives a reading. 6 Inst Instal alll tthe he sens sensor or..

Checking supply cable, water  switch, fuel filter  Tools: 88890074 Multimeter  1 NOTICE! Turn NOTICE!  Turnmain the starter to position (If MCC, turn batterykey switches off.) 0. 2 Discon Disconnec nectt the c conne onnecto ctorr fro from m the wa water ter in in fuel switch. 3 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. 4 NOTICE! NOTICE! Turn  Turn the starter key to position 1. Measurement points

Nominal value

Red/Blue conductor Black conductor 

U ≈ Battery voltage

160

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Checking negative cable, water  switch, fuel filter  Tools: 88890074 Multimeter  1 NOTICE!  Cut the current with the main switch. NOTICE! Cut 2 Dis Discon connec nectt the co conne nnecto ctorr from tthe he water water iin n fuel switch. 3 Use mul multim timeter eter 888 8889007 90074 4 to d do o res resist istanc ance e measurement towards the engine control unit. Measurement points

Nominal value

Black conductor - Battery negative

R≈0Ω

Checking signal cable, water  switch, fuel filter  Tools: 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Dis Discon connec nectt the co conne nnecto ctorr from tthe he water water iin n fuel switch. 3 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. 4 NOTICE! NOTICE! Turn  Turn the starter key to position 1. Measurement points

Nominal value

Yellow conductor - Black conductor 

U ≈ Battery voltage x 0,8

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Checking the water in fuel switch, fuel filter  2 1

D9, D12, D16 1 Remove Remove the the con connec nector tor.. Rem Remove ove th the e water water sw switc itch h from the fuel fine filters.

+24V 3

+24V

H2O P0007196

 

1

Re Red d cond conduc ucto torr in conn connec ecto tor. r.

2

Yel Yellow low con conduc ductor tor in connec connector tor..

3

Bla Black ck conduc conductor tor in connec connector tor..

Make suremay that run a collection vessel some fuel out of the filter. is available as 2 Conn Connec ectt tthe he rred ed wire wire (2) to a +24 V power source. Use multimeter 88890074 for voltage measurement. Connect the multimeter between the yellow wire (1 (1) in the connector and the red wire (2 ( 2). Connect the connector's black wire (3 (3) to ground (-). The multimeter should display 0 V. 3 Dip the the monit monitor or con contac tactt pin pins s int into o a dish dish of wat water. er. The multimeter must show 23-24 V when there is water between the contact pins. 4 The mult multime imeter ter s shoul hould d dis displa play y 0 V whe when n the s swit witch ch is lifted out of the water. D11 1 Remo Remove ve the the swi switc tch. h. 2 Disconn Disconnect ect tthe he co connec nnector tor fr from om the wate waterr in fuel fuel switch. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurements. Measurement points

Nominal value

Moni Mo nito torr dipp dipped ed in wate water. r.

R≈0 Ω

Monitor dipped in fuel.

R≈∞Ω

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Checking camshaft sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 

1 NOTICE! Cut NOTICE! Cut the current with the main switch. 2 Und Undo o the c conn onnect ector or fr from om the the sen sensor sor and and re remov move e the sensor from the cylinder head. Check that the sensor has no external damage or  swarf adhering to it. 3 Con Connect nect a adap dapter ter ca cable ble 9 9998 998534 534 or 8 88567 85675 5 to th the e sensor. Do not connect the other end of the cable. 4 Use m mult ultime imeter ter 98 981251 12519 9 to mea measure sure resi resista stance nces. s.

      5        7      6       5       8       8

Measurement points

Nominal value

1–2

R ≈ 0.9 kΩ*

NOTICE! * NOTICE!  * ±10% at 20 °C (68 °F).

      5

      4         3

     2

V

     1

 2

885 675

5 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. Move a metal object rapidly back and forth at a distance of no more than 1 mm in front of the sensor. Check that the multimeter gives a reading.

1

6 Inst Instal alll tthe he sens sensor or..

      5        7      6       5       8       8       4         3

     2      1

885 675 P0008931

 

1

 2

      5

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Checking supply cable, oil level switch Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Disconn Disconnect ect th the e connect connector or fro from m the senso sensorr Conn Connect ect break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. 4 NOTICE! NOTICE! Turn  Turn the starter key to position 1. Measurement points

Nominal value

1-2

U ≈ Battery voltage

 

Checking negative cable, oil level switch Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Disconn Disconnect ect th the e connect connector or fro from m the senso sensorr Conn Connect ect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit. Measurement points

Nominal value

2 - Battery negative

R≈0Ω

NOTICE! Battery negative (–) on alternator or starter  NOTICE! Battery motor.

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Checking the oil level switch D11, D9 Tools: 9998534 Break-out cable 885675 Break-out cable 1 Put a s suit uitabl able e vess vessel el undern underneath eath tthe he oi oill pan pan.. 2 Rel Releas ease e the co conne nnecto ctorr and re remov move e the mo monit nitor  or  from the engine. NOTICE! Temporarily install a bottom plug (M18 x NOTICE! Temporarily 1.5) with gasket (part # 960632 and 11998) in the oil sump to prevent oil running out.

 WARNING! Hot oil and hot surfaces can cause burns.

 A

 

Oil

3 Con Connect nect b brea reak-o k-out ut cable cable 99 99985 98534 34 or 88 88567 5675 5 to the oil level switch. Connect a +12/24 V power source to cable 1. Connect a +12/24 V (1 W) supply between cable 3 and a +12/24 V power source. Connect cable 2 to battery negative (-). 4 Put the the swit switch ch vertic verticall ally y into a ve vesse ssell contain containing ing engine oil. The bulb should light up. 5 Lift Lift the se senso nsorr up out o off the oil oil bath bath and chec check k tha thatt the bulb goes out.

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Checking the oil level sensor  D12, D13, D16 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 

1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Connec Connectt brea break-o k-out ut cable cable 99985 9998534 34 or 88 88567 5675 5 to th the e sensor. Do not connect the other end of the adapter  cable. 3 Use mult multime imeter ter 8 8889 889007 0074 4 for rresi esista stance nce measurement. Measurement points

Nominal value

1-2

R ≈ 10–14 Ω

NOTICE! Even if the nominal value is correct the NOTICE! Even sensor could be faulty.

P0007205

 

166

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Injector trim The electronic trimming strategy is used to ensure that all injectors work with nominal injection times and fuel quantities. This is achieved by adjusting the beginning and end of the electronic wave pattern for every actuator. In this way compensation is made for the spread of activation and deactivation times of the two actuatorsdue in each injector,between and deviations in fuelnozzle delivery to variations the different flows are also corrected. NOTICE! Write down the new injector codes before NOTICE! Write installation. The codes comprise 6 characters on 2-pin injectors and are located on the injector's electrical connector below the SN number.

P0001354

2 pin injector 

 

On 4 pin injectors the code comprises 9 characters located on the injector's electrical connector below the SN number. 1 Co Conne nnect ct the the V VOD ODIA IA tool tool.. 2 Go in into to the the “Servi “Service ce an and d mainten maintenanc ance” e” men menu u in VODIA. 3 Sel Select ect “Pa “Param rameter eter,, program programmin ming”. g”. 4 Click “R “Run”. 5 Sel Select ect th the e cylinde cylinderr numb number er cor corres respon pondin ding g to the injector that has been changed. 6 Ent Enter er the the new inject injector or co code. de. C Clic lick k “OK”. “OK”. 7 Clo Close se “Pa “Parame rameter ter,, prog program rammin ming”. g”. 8 VODIA will instruct instruct you to “T “Turn urn off the ma main in sw switch”; itch”; follow subsequent instructions. 9 Report Report pa parame rameter ters s acc accord ording ing to iitem tems s 10-13 10-13 in "Program the control unit".

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Checking the injector coils Tools: 9998699 Break-out box 9990014 Break-out cable 88890074 Multimeter  1 Turn Turn the the starte starterr ke key y to pos positi ition on 0. 0. (If MCC, turn main battery switches off.) 2 Cut the current current wit with h the the main main switc switch. h. IMPORTANT! The system must be disconnected from the electrical supply and the ignition key must be in the 0 position when the engine control unit connector is disconnected or connected. 3 Connec Connectt 99986 9998699 99 BreakBreak-out out box and 9990014 Break-out cable as described in section Connection of 9998699 Break-out box to EMS 2   in in chapter Repair Instructions, page 61. 61. 4 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurements.

D9, D12, D16

Measurement points* Pin no.

Nominal value at 20 °C (68 °F)

24 – 59

R ≈ 3.5-4.5 Ω

16 – 59

R ≈ 3.5-4.5 Ω

32 – 59

R ≈ 3.5-4.5 Ω

56 – 60

R ≈ 3.5-4.5 Ω

48 – 60

R ≈ 3.5-4.5 Ω

40 – 60

R ≈ 3.5-4.5 Ω

24 – Battery negative terminal**

Open circuit

16 – Battery negative terminal**

Open circuit

32 – Battery negative terminal**

Open circuit

56 – Battery negative terminal**

Open circuit

48 – Battery negative terminal**

Open circuit

40 – Battery negative terminal**

Open circuit

NOTICE! The measurement should exclude short NOTICE! The circuiting or open circuit in the cable to the injector. * Black connector A. ** Battery negative (–) on alternator or starter motor. IMPORTANT!

Take great care when measuring inside the connector  to ensure that no pins are damaged.

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D11 Measuring points in connector A Pin no.

Nominal value at 20 °C (68 °F)

20 – 62

R ≈ 1.4-3 Ω

12 – 62

R ≈ 1.4-3 Ω

28 – 62

R ≈ 1.4-3 Ω

24 – 59 16 – 59

R ≈ 1.4-3 Ω R ≈ 1.4-3 Ω

32 – 59

R ≈ 1.4-3 Ω

52 - 61

R ≈ 1.4-3 Ω

44 - 61

R ≈ 1.4-3 Ω

36 - 61

R ≈ 1.4-3 Ω

56 - 60

R ≈ 1.4-3 Ω

48 - 60

R ≈ 1.4-3 Ω

40 - 60

R ≈ 1.4-3 Ω

20 - 57

Open circuit

12 - 57

Open circuit

28 - 57

Open circuit

24 - 57

Open circuit

16 - 57

Open circuit

32 - 57

Open circuit

52 - 57

Open circuit

44 - 57

Open circuit

36 - 57

Open circuit

56 - 57

Open circuit

48 - 57

Open circuit

40 - 57

Open circuit

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Checking negative cable, intake manifold temperature sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit.

 

Measurement points

Nominal value

D9, D12

4 - Battery negative*

R≈0Ω

D11, D16

1 - Battery negative*

R≈0Ω

NOTICE! * Battery negative (–) on alternator or starter  NOTICE! * motor.

Checking signal cable, intake manifold temperature sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Turn Turn the the starte starterr ke key y to pos positi ition on 1. 1. 4 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. Measurement points

Nominal value

D9, D12

3-4

U≈5V

D11, D16

1-2

U≈5V

5 Tu Turn rn off off iign gnit itio ion. n. 6 Connec Connectt bre breakak-out out cabl cable e 999 999853 8534 4 or 88 88567 5675 5 between the sensor and engine control unit. 7 Tu Turn rn on igni igniti tion on.. Measurement points

Nominal value

D9, D12

3-4

U ≈ 0.5 - 4.5 V*

D11, D16

1-2

U ≈ 0.5 - 4.5 V*

NOTICE! * Depending on performance. NOTICE! *

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30-2 Fault Tracing

Checking the intake manifold temperature sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Dis Discon connec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 between the sensor and engine control unit. NOTICE! Do not connect the other end of the NOTICE! Do adapter cable to the engine cable harness, as this may cause incorrect measurements. 3 Use mul multim timeter eter 888 8889007 90074 4 to measure measure the the resistance of the sensor.

 

D9, D12

D11, D16

Measurement points

Nominal value

Measurement points

Nominal value

3-4

R ≈ 48401 Ω +/- 3088 Ω (at –20° C (–4° F))

1-2

R ≈ 9426 Ω +/- 470 Ω (at –10° C (–4° F))

3-4

R ≈ 16233 Ω +/- 895 Ω (at 0° C (32° F))

1-2

R ≈ 5896 Ω +/- 332 Ω (at 0° C (32° F))

3-4

R ≈ 6201 Ω +/- 283 Ω (at 20° C (68° F))

1-2

R ≈ 2511 Ω +/- 109 Ω (at 20° C (68° F))

3-4

R ≈ 2648 Ω +/- 97 Ω (at 40° C (104° F))

1-2

R ≈ 1200 Ω +/- 47 Ω (at 40° C (104° F))

3-4

R ≈ 1240 Ω +/- 42 Ω (at 60° C (140° F))

1-2

R ≈ 612 Ω +/- 22 Ω (at 60° C (140° F))

3-4

R ≈ 627 Ω +/- 26 Ω (at 80° C (176° F))

1-2

R ≈ 329 Ω +/- 11 Ω (at 80° C (176° F))

3-4

R ≈ 339 Ω +/- 15 Ω (at 100° C (212° F))

1-2

R ≈ 186 Ω +/- 5 Ω (at 100° C (212° F))

3-4

R ≈ 195 Ω +/- 10 Ω (at 120° C (248° F))

1-2

R ≈ 110 Ω +/- 4 Ω (at 120° C (248° F))

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Checking supply cable, oil pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Disconn Disconnect ect th the e connect connector or fro from m the senso sensorr Conn Connect ect break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. 4 NOTICE! NOTICE! Turn  Turn the starter key to position 1. Measurement points

Nominal value

1-4

U≈5V

 

Checking signal cable, oil pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Disconn Disconnect ect th the e connect connector or fro from m the senso sensorr Conn Connect ect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit. Measurement points

Nominal value

2 - Battery negative*

R ≈ 80 - 120 kΩ

NOTICE! * The measurement should exclude short NOTICE! * circuiting or open circuit in the cable to the engine control unit.

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Checking the oil pressure sensor  NOTICE! Combined sensor, oil pressure and oil NOTICE! Combined temperature (engine). Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. 4 NOTICE!  Turn the starter key to position 1. NOTICE! Turn

 

Measurement points

Nominal value

2-4

U ≈ 0,5 V*

NOTICE! * NOTICE!  * At normal atmospheric pressure

Checking negative cable, seawater  pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 

1 NOTICE!  Cut the current with the main switch. NOTICE! Cut 2 Dis Discon connec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 8890074 0074 to do resi resista stance nce measurement towards the engine control unit.

4

9998534 P0007190

Measurement points

Nominal value

4 - Battery negative terminal

R≈0Ω

 

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Checking supply cable, seawater  pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn off ignition. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. 4 NOTICE! NOTICE! Turn  Turn on ignition. Measurement points

Nominal value

1–4

U≈5V

 

Checking signal cable, seawater  pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE!  Cut the current with the main switch. NOTICE! Cut 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit. Measurement points 2 - Battery negative terminal

Nominal value R ≈ 80 - 120 kΩ

NOTICE! Measurement is done to eliminate short NOTICE! Measurement circuiting or breaks in the cable to the engine control unit.

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30-2 Fault Tracing

Checking the seawater pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 

1 NOTICE! Turn NOTICE! Turn off ignition. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co conne nnector ctor ffrom rom th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. 4 Tu Turn rn on igni igniti tion on.. Measurement points

Nominal value

2–4

U ≈ 0,5 V

 

Checking negative cable, piston cooling pressure sensor  D12, D16 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 Cut the curr current ent w with ith the main main swi switch tch.. 2 Discon Disconnec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mul multim timeter eter 888 8889007 90074 4 to d do o res resist istanc ance e measurement towards the engine control unit. Measurement points

Nominal value

2 - Battery negative terminal

R≈0Ω

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Checking power supply cable, piston cooling pressure sensor  D12, D16 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. 4 Turn Turn the the starte starterr ke key y to pos positi ition on 1. 1. Measurement points

Nominal value

1–2

U ≈ Battery voltage

 

Checking negative cable, piston cooling pressure sensor  D11, D9 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 Cut the current current wit with h the the main main switc switch. h. 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit.

4

9998534 P0007186

 

Measurement points

Nominal value

4 - Battery negative terminal

R≈0Ω

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30-2 Fault Tracing

Checking power supply cable, piston cooling pressure sensor  D11, D9 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement.

4

4 Turn Turn the the start starter er key key to to po posit sition ion 1. 9998534

Measurement points

Nominal value

1–4

U≈5V

P0007186

 

Checking the piston cooling pressure sensor  D11 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 Tur Turn n th the e start starter er key key to to po posit sition ion 0. (If MCC, turn main battery switches off.) 2 break-out Dis Discon connec nectcable t the co connec nnector tor or fr from om the s sens ensor or Con Connec nectt 9998534 885675 between the sensor and engine control unit. 3 Turn Turn the the start starter er key key to to po posit sition ion 1. 4 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. Measurement points

Nominal value

2–4

U ≈ 0,5 V

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30-2 Fault Tracing

Checking negative cable, air inlet pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit.

 

Measurement points

Nominal value

D9, D12

4 - Battery negative*

R≈0Ω

D11, D16

1 - Battery negative*

R≈0Ω

NOTICE! * Battery negative (–) on alternator or starter  NOTICE! * motor.

Checking signal cable, air inlet pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE!  Cut the current with the main switch. NOTICE! Cut 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit. Measurement points

Nominal value

D9, D12

2 - 4*

R ≈ 80 - 120 kΩ

D11, D16

4 - 1*

R ≈ 80 - 120 kΩ

NOTICE! * measurements are taken to eliminate a NOTICE! * short circuit or open circuit in the engine control unit cable.

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30-2 Fault Tracing

Checking the air inlet pressure sensor  NOTICE! Combined sensor, charge air pressure/ NOTICE! Combined charge air temperature Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co conne nnector ctor ffrom rom th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Turn Turn the the start starter er key key to to po posit sition ion 1. 4 Use mul multim timeter eter 888 8889007 90074 4 to do volt voltage age measurement towards the engine control unit.

 

Measurement points

Nominal value

D9, D12 D11, D16

U ≈ 1,2 V* U ≈ 1,1 V*

2-4 1-4

NOTICE! * At normal atmospheric pressure NOTICE! *

Checking supply cable, air inlet pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 Tur Turn n th the e start starter er key key to to po posit sition ion 0. (If MCC, turn main battery switches off.) 2 Dis Discon connec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Turn Turn the the start starter er key key to to po posit sition ion 1. 4 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. Measurement points

Nominal value

D9, D12

1-4

U≈5V

D11, D16

1-3

U≈5V

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30-2 Fault Tracing

Checking negative cable, coolant temperature sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE!  Cut the current with the main switch. NOTICE! Cut 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit.

 

Measurement points

Nominal value

1 - Battery negative*

R≈0Ω

NOTICE! * Battery negative (–) on alternator or starter  NOTICE! * motor.

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Checking signal cable, coolant temperature sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 

1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Con Connect nect b brea reak-o k-out ut cable cable 99 99985 98534 34 or 88 88567 5675 5 to the cable harness connector to the engine control contro l unit. 3 Use mul multim timeter eter 888 8889007 90074 4 to do volt voltage age measurement towards the engine control unit. 4 Turn Turn the the start starter er key key to to po posit sition ion 1. Measurement points

Nominal value

1-2

U≈5V

5 Tu Turn rn off off iign gnit itio ion. n.

  6 Connect Connect bre breakak-out out cabl cable e 999 9998534 8534 or 88 885675 5675 between the sensor and engine control unit. 7 Tu Turn rn on igni igniti tion on.. Measurement points

Nominal value

1-2

U ≈ 0,5 - 4,5V*

NOTICE! * Depending on temperature. NOTICE! *

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Checking the coolant temperature sensor   

Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the sensor. Do not connect the other end of the adapter cable. 3 Use mul multim timete eterr 888900 88890074 74 to mea measur sure e the resistance of the sensor.

Set point at (Measurement points 1-2): 100 °C (212 °F) 80 °C (176 °F) 60 °C (140 °F) 40 °C (104 °F) 20 °C (68 °F) 0 °C (32 °F)

 

R ≈ 104 Ω ±4 Ω R ≈ 190 Ω ±8 Ω R ≈ 375 Ω ±20 Ω R ≈ 800 Ω ±50 Ω R ≈ 1870 Ω ±140 Ω R ≈ 4930 Ω ±440 Ω

P0005119

°C Ω

Coolant Temperature Resistance

 

Checking supply cable, coolant switch Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn off ignition (If MCC, turn main battery switches off.) 2 Disconn Disconnect ect th the e connect connector or fro from m the senso sensorr Conn Connect ect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement.

4 Tu Turn rn on igni igniti tion on..

182

Measurement points

Nominal value

1-2

Battery voltage x 0.8

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Checking negative cable, coolant switch Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE!  Cut the current with the main switch. NOTICE! Cut 2 Discon Disconnec nectt the co conne nnector ctor ffrom rom th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 8890074 0074 to do rresi esista stance nce measurement towards the engine control unit. Measurement points

Nominal value

2 - Battery negative

R≈0Ω

 

Checking the coolant switch Tools: 88890074 Multimeter  1 Undo Undo the co conne nnecto ctorr and re remov move e the sw switc itch h fro from m the expansion tank.

 WARNING! Stop the engine and let it cool before starting work on the cooling system. Hot fluids and hot surfaces can cause burns. 2 Use mult multime imeter ter 8 8889 8890074 0074 to do rresi esista stance nce measurement against the switch. Measurement points

Nominal value

Blue conductor - Black conductor 

R≈∞Ω (Coolant level is ok.)

3 Move a magnet magnet a alon long g the swi switch tch a and nd ob obser serve ve the the resistance value. Measurement points

Nominal value

Blue conductor - Black conductor 

R≈0Ω (Coolant level too low)

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30-2 Fault Tracing

Checking supply cable, crankcase pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Turn Turn the the starte starterr ke key y to pos positi ition on 1. 1. 4 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. Measurement points

Nominal value

1-4

U≈5V

 

Checking negative cable, crankcase pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit.

4

9998534 P0007186

 

Measurement points

Nominal value

4 - Battery negative*

R≈0Ω

NOTICE! Battery negative (–) on alternator or starter  NOTICE! Battery motor.

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30-2 Fault Tracing

Checking signal cable, crankcase pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 Cut the curr current ent w with ith the main main swi switch. tch. 2 Dis Discon connec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 8890074 0074 to do resi resista stance nce measurement towards the engine control unit. NOTICE! Measurements are taken to eliminate a short NOTICE! Measurements circuit or open circuit in the engine control unit cable. Measurement points

Nominal value

2 - Battery negative*

R ≈ 80 - 120 kΩ

NOTICE! Battery NOTICE!  Battery negative (–) on alternator or starter 

 

motor.

Checking the crankcase pressure sensor  Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 Turn Turn the the start starter er key key to to po posit sition ion 0. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co conne nnector ctor ffrom rom th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 between the sensor and engine control unit. 3 Turn Turn the the start starter er key key to to po posit sition ion 1. 4 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. Measurement points

Nominal value

2-4

U ≈ 2,9 V*

NOTICE! * NOTICE!  * At normal atmospheric pressure

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30-2 Fault Tracing

Checking signal cable, exhaust temperature sensor  Tools: 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn off ignition. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the connect connector or fr from om th the e sen sensor  sor  3 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. 4 NOTICE!  Turn on ignition. NOTICE! Turn Measurement points

Nominal value

1-2

U≈5V

 

Checking negative cable, exhaust temperature sensor  Tools: 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Discon Disconnec nectt the connect connector or fr from om th the e sen sensor  sor  3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit. Measurement points

Nominal value

1 - Battery negative

R≈0Ω

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30-2 Fault Tracing

Checking exhaust temperature sensor  Tools: 88890074 Multimeter  1 Cut the curr current ent w with ith the main main swi switch tch.. 2 Undo Undo the c conn onnect ector or fr from om the the sen sensor sor and and re remov move e the sensor from the exhaust elbow. Check that the sensor has no visible damage. 3 Use multi multimet meter er 9812519 9812519 tto o meas measure ure th the e resi resista stance nce between the two sensor contact pins. The resistance must correspond to the values in the table.

  °C Ω

Exhaust Temperature Resistance

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Measuremen t points

Nominal re resistance value

Nominal voltage value measured across the sensor 

1-2

R ≈ 185 Ω at -20° C at

U ≈ 0.78 V at -20° C

1-2

R ≈ 200 Ω at 0° C

U ≈ 0.84 V at 0° C

1-2

R ≈ 220 Ω at 25° C

U ≈ 0.90 V at 25° C

1-2

R ≈ 238 Ω at 50° C

U ≈ 0.96 V at 50° C

1-2

R ≈ 276 Ω at 100° C

U ≈ 1.08 V at 100° C

1-2

R ≈ 313 Ω at 150° C

U ≈ 1.19 V at 150° C

1-2

R ≈ 349 Ω at 200° C

U ≈ 1.29 V at 200° C

1-2

R ≈ 385 Ω at 250° C

U ≈ 1.39 V at 250° C

1-2

R ≈ 420 Ω at 300° C

U ≈ 1.48 V at 300° C

1-2

R ≈ 454 Ω at 350° C

U ≈ 1.56 V at 350° C

1-2

R ≈ 488 Ω at 400° C

U ≈ 1.64 V at 400° C

1-2

R ≈ 521 Ω at 450° C

U ≈ 1.71 V at 450° C

1-2

R ≈ 554 Ω at 500° C

U ≈ 1.78 V at 500° C

1-2

R ≈ 618 Ω at 600° C

U ≈ 1.91 V at 600° C

1-2

R ≈ 679 Ω at 700° C

U ≈ 2.02 V at 700° C

1-2

R ≈ 738 Ω at 800° C

U ≈ 2.12 V at 800° C

1-2

R ≈ 795 Ω at 900° C

U ≈ 2.21 V at 900° C

1-2

R ≈ 849 Ω at 1000° C

U ≈ 2.30 V at 1000° C

Checking negative cable, oil temperature sensor  D11, D12, D9 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Cut NOTICE! Cut the current with the main switch. 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the engine control unit.

4

9998534 P0007186

 

Measurement points

Nominal value

4 - Battery negative*

R≈0Ω

NOTICE! * Battery negative (–) on alternator or starter  NOTICE! * motor.

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30-2 Fault Tracing

Checking power supply cable, oil temperature sensor  D11, D12, D9  

Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. 4 NOTICE!  Turn the starter key to position 1. NOTICE! Turn

 

Measurement points

Nominal value

3-4

U≈5V

5 Tu Turn rn off off iign gnit itio ion. n. 6 Connect Connect bre breakak-out out cabl cable e 999 9998534 8534 or 88 885675 5675 between the sensor and engine control unit. 7 Tu Turn rn on igni igniti tion on.. Measurement points

Nominal value

3-4

U ≈ 0.5 - 4.5 V (depending on the temperature)

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30-2 Fault Tracing

Checking the oil temperature sensor  D11, D12, D9  

NOTICE! * Combined sensor, oil pressure and oil NOTICE! * temperature (engine). Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the sensor. Do not connect the other end of the adapter cable. 3 Use mul multim timete eterr 888900 88890074 74 to mea measur sure e the resistance of the sensor.

 

Measuremen Nominal value t points

kΩ

P0007238

C

kΩ

Resistance

°C

Engine Oil Temperature

3-4

R ≈ 4981Ω +/- 503Ω (at 0° C (32° F))

3-4

R ≈ 1900Ω +/- 163Ω (at 20° C (68° F))

3-4

R ≈ 809Ω +/- 59Ω (at 40° C (104° F))

3-4

R ≈ 378Ω +/- 24Ω (at 60° C (140° F))

3-4

R ≈ 191Ω +/- 10Ω (at 80° C (176° F))

3-4

R ≈ 104Ω +/- 5Ω (at 100° C (212° F))

3-4

R ≈ 60Ω +/- 3Ω

 

(at 120° C (248° F))

190

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Checking negative cable, oil temperature sensor  D13, D16 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! NOTICE! Cut  Cut the current with the main switch. 2 Dis Discon connec nectt the co connec nnector tor fr from om the s sens ensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mult multime imeter ter 8 8889 8890074 0074 to do resi resista stance nce measurement towards the engine control unit. Measurement points

Nominal value

4 - Battery negative*

R≈0Ω

NOTICE! * Battery negative (–) on alternator or  NOTICE! * starter motor.

 

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30-2 Fault Tracing

Checking signal cable, oil temperature sensor  D13, D16 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn off ignition. (If MCC, turn main battery switches off.) 2 Discon Disconnec nectt the co conne nnecto ctorr from th the e sens sensor or Con Connec nectt break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit. 3 Use mul multim timete eterr 88890 88890074 074 for vol voltag tage e measurement. Measurement points

Nominal value

3-4

U≈5V

4 Tu Turn rn off off iign gnit itio ion. n. 5 Connec Connectt bre breakak-out out cabl cable e 999 999853 8534 4 or 88 88567 5675 5 between the sensor and engine control unit. 6 Tu Turn rn on igni igniti tion on..

 

Measurement points

Nominal value

3-4

U ≈ 0,5 - 4,5 V (depending on the temperature)

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Checking the oil temperature sensor  D13, D16  

Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter  1 NOTICE!  Cut the current with the main switch. NOTICE! Cut 2 Connect Connect b brea reak-o k-out ut cable cable 99 99985 98534 34 or 88 88567 5675 5 to the sensor. Do not connect the other end of the adapter  cable. 3 Use mult multime imeter ter 8 8889 8890074 0074 to do resi resista stance nce measurements. Measuremen Nominal value t points

 

3-4

R ≈ 4981Ω +/- 503Ω (at 0° C (32° F))

3-4

R ≈ 1900Ω +/- 163Ω (at 20° C (68° F))

3-4

R ≈ 809Ω +/- 59Ω (at 40° C (104° F))

3-4

R ≈ 378Ω +/- 24Ω (at 60° C (140° F))

3-4

R ≈ 191Ω +/- 10Ω (at 80° C (176° F))

3-4

R ≈ 104Ω +/- 5Ω (at 100° C (212° F))

3-4

R ≈ 60Ω +/- 3Ω (at 120° C (248° F))

kΩ

P0007238

 

C

kΩ

Resistance

°C

Engine Oil Temperature

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30-2 Fault Tracing

Checking the starter motor solenoid Tools: 88890074 Multimeter  1 NOTICE! Turn NOTICE! Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Undo Undo tthe he red red/y /yel ello low w ca cabl ble. e. 3 Use mult multime imeter ter 8 8889 889007 0074 4 to do resist resistanc ance e measurement towards the relay. Nominal value R ≈ 2-12 Ω* NOTICE! * Depending on whether the engine is NOTICE! * equipped with 12 V or 24 V.  A

Measurement points points

 

Checking the pre-start relay 1 NOTICE! NOTICE! Turn  Turn the starter key to position 0. (If MCC, turn main battery switches off.) 2 Access Access the fuse fuses s by removi removing ng th the e co cover ver.. 3 Ident Identif ify y the pre pre-s -star tartt rel relay ay.. 4 Remove Remove the the re relay lay from from its its prote protecti ctive ve box. box. 5 Undo Undo the the relay relay from from the rrela elay y so socke cket. t. 6 Measure Measure the the resis resistan tance ce betwee between n pin pins s 85 and and 86 on the relay. Check that there is no short circuit or open circuit.

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Checking the external stop voltage potential Tools: 9990014 Break-out cable 9998699 Break-out box 88890074 Multimeter  1 Tu Turn rn off off igni igniti tion on (If MCC, turn main battery switches off.) 2 Cut the curr current ent w with ith the main main swi switch tch.. 3 Connect Connect 999 999869 8699 9B Break reak-ou -outt box box and 9990014 Break-out cable as described in section Connection of 9998699 Break-out box to EMS 2   in in chapter Repair Instructions, page 61. 61. 4 Tu Turn rn on main main swit switch ch.. 5 Turn Turn on ign gniiti tion on 6 Use mul multim timeter eter 888 8889007 90074 4 fo forr volta voltage ge measurement. Measurement points Pin A27 for the EMS2 (color: green) - Battery negative terminal

Nominal value U ≈ 0.8 x Battery voltage (stop not activated)

Pin A27 for the EMS2 (color: green) - Battery negative terminal

U ≈ Battery voltage (stop activated)

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37-0 Wiring Diagrams

37-0 Wiring Diagrams NOTICE! Please NOTICE!  Please refer to publ. to publ. no. 47702819 47702819..

196

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39-0 General

39-0 General Adjustment parameters for lowspeed or trolling function The lowspeed or trolling function can be fine-tuned using VODIA. Go into “parameter programming” and adjust the parameters given below. For Volvo Penta Lowspeed FYE (Maximum slip factor for VP Lowspeed - gives the value for maximum speed reduction). Enter a value within the range specified for the parameter. FYF (Upper lever limit for slip function at forward specifies within how large a part of the lever movement the function will be active when forward gear gea r has been selected). Enter a value within the range specified for  the parameter. FYG (Upper lever limit for slip function at reverse specifies the amount of lever travel in which the low speed function is active, when reverse gear has been selected). Enter a value within the range specified for  the parameter. For Volvo Penta Trolling HAZ (Maximum slip factor for VP Trolling - specifies the value for maximum speed reduction). Enter a value within the range specified for the parameter.

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Checking propeller rotation The connectors for the gear shift solenoids are connected at the factory for left-hand rotation with ”Forwards” gear. The cables are marked ”PRIMARY” and ”SECONDARY”.

ZF311 and ZF325 1

Check that the connectors are correctly joined up, since there is no corresponding marking on the reversing gear. Please refer to the adjacent illustrations which show the cable connections for lefthand rotation. Shift the connectors on the solenoid valves over to obtain right-hand rotation. 2

6

IMPORTANT!

5

3 4

Check that the trolling valve cable is correctly connected to the trolling valve*. NOTICE! * Only reversing gear ZF311 and ZF325 can NOTICE! * be equipped with an electrically controlled trolling valve for the low speed or trolling function (optional). 1 Oil pressu pressurere- /oil /oil tem temper peratur ature e se senso nsor  r  2 Pr Prim imar ary ys sol olen enoi oid dv val alve ve 3 Slip valve

P0008761

4 Se Seco cond ndar ary y so sole lenoi noid d va valv lve e The illustration shows the reversing gear with trolling valve and cables connected for left-hand rotation.

  Twin Disc MG5114DC

5 Cabl Cable e ma mark rkin ing g ”S ”SEC ECON ONDA DARY RY”” 6 Cabl Cable em mark arkin ing g “P “PRI RIMA MARY RY””

1 Pr Prim imar ary ys sol olen enoi oid dv val alve ve 2 Cabl Cable em mark arkin ing g “P “PRI RIMA MARY RY”” 4 1 3 2

P0008762

3 Cabl Cable e ma mark rkin ing g ”S ”SEC ECON ONDA DARY RY”” 4 Se Seco cond ndar ary y so sole lenoi noid d va valv lve e

The illustration shows the cables connected for left-hand rotation.

 

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39-0 General

Index MID 128: Engine control unit Caption

PID

PPID SID

PSID FMI

MID 128, PID 20, Extended Range Engine Coolant  Pressure, page 74

20

1, 3, 5

MID 128, PID 94 Fuel Delivery Pressure, page 76  MID 128, PID 97 Water in fuel indicator, page 79

94 97

1, 3, 5, 7 0, 3

MID 128, PID 98 Engine oil level, page 83

98

1, 3

MID 128, PID 100 Engine oil pressure, page 86 

100

1, 3, 5

MID 128, PID 105 Intake manifold temperature, page 89

105

0, 4, 5

MID 128, PID 106 Air inlet pressure, page 92 

106

0, 3, 5

MID 128, PID 110 Engine coolant temperature, page 95 

110

0, 4, 5

MID 128, PID 111 Coolant level, page 98 

111

1, 3

MID 128, PID 153 Crankcase pressure, page 100 

153

0, 3, 5

MID 128, PID 158 ECU battery potential, page 103

158

1

MID 128, PID 163, Transmission range attained, page 104

163

9

MID 128, PID 173 Exhaust gas temperature, page 105 

173

0, 4, 5

MID 128, PID 175 Engine oil temperature, page 107  (D9,  (D9, D11, 175 D12)

0, 4, 5

Engine Oil Temperature ( Temperature (D D16)

175

0, 4, 5

MID 128, PID 190 Engine speed, page 113

190

0

MID 128, PPID 3 Starter Output, page 114

3

3, 4, 5

MID 128, PPID 6 Key off input sensor, page 115 

6

4, 11

MID 128, PPID 8 Piston Cooling Oil Pressure, page 117  (D9,  (D9, D12, D16)

8

1

Piston cooling oil pressure ( pressure (D D11)

8

1, 3, 5

MID 128, PPID 98 Engine sync acknowledge, page 121

98

9

MID 128, PPID 117 Engine protection status, page 122 

117

7

MID 128, PPID 132 Throttle Calibrated Position, page 123

132

9

MID 128, PPID 267, Sea water pressure, page 124 MID 128, SID 1/2/3/4/5/6 Injector # 1-6, page 126 

267 1/2/3/4/5/6

1, 3, 5 3, 4, 5, 7, 12

MID 128, SID 21 Engine position, page 130 

21

2, 3, 8

MID 128, SID 22 Timing sensor, crank, page 133

22

2, 3, 8

MID 128, SID 32, Wastegate output driver, page 137 

32

3, 4, 5

MID 128, SID 89 Air Compressor Actuator Circuit, page 140 

89

3, 4, 5

MID 128, SID 232 5 V supply, page 142 

232

3, 4

MID 128, SID 240 Program memory, page 143

240

2

MID 128, SID 254 Controller 1, page 144

254

3, 12

MID 128, SID 231 SAE J1939 data link, page 145 

231

2, 9

MID 128, PSID 112 Exhaust Manifold Water Temperature Sensor #1, page 146 

112

0, 3, 4, 5

216

MID 128, PSID 216 Data Link, MID187, page 148 

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39-0 General

MID 158: Power module Caption

PSID

FMI

MID 158, PSID 1, Primary battery circuit, page 149

1

3, 4

MID 158, PSID 2, Secondary battery circuit, page 150 

2

3, 4

MID 158, PSID 4, 30 supply fuse, page 151

4

6

MID 158, PSID 5, EMS supply fuse, page 152 

5

5, 6

MID 158, PSID 6, Extra supply fuse, page 154

6

6

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Index A  About this Workshop manual..................................... 2  Adjustment parameters for low-speed or trolling function................................................................... 197 C Checking camshaft sensor..................................... 163 Checking exhaust temperature sensor................... 187 Checking flywheel sensor....................................... 160 Checking negative cable, air inlet pressure sensor  178 Checking negative cable, coolant pressure sensor  155 Checking negative cable, coolant switch................ 183 Checking negative cable, coolant temperature sensor..................................................................... 180 Checking negative cable, crankcase pressure sensor..................................................................... 184 Checking negative cable, exhaust temperature sensor..................................................................... 186 Checking negative cable, fuel pressure sensor...... 157 Checking negative cable, intake manifold temperature sensor................................................ 170 Checking negative cable, oil level switch............... 164 Checking negative cable, oil temperature sensor............................................................. 188, 188, 191 Checking negative cable, piston cooling pressure sensor.............................................. 175, 175, 176 Checking negative cable, seawater pressure sensor..................................................................... 173 Checking negative cable, water switch, fuel filter... 161 Checking power supply cable, oil temperature sensor..................................................................... 189 Checking power supply cable, piston cooling pressure sensor.............................................. 176, 176, 177 Checking propeller rotation.................................... 198 Checking signal cable, air inlet pressure sensor.... 178 Checking signal cable, coolant pressure sensor.... 156 Checking signal cable, coolant temperature sensor  181 Checking signal cable, crankcase pressure sensor  185 Checking signal cable, exhaust temperature sensor..................................................................... 186 Checking signal cable, fuel pressure sensor.......... 158 Checking signal cable, intake manifold temperature sensor................................................ 170 Checking signal cable, oil pressure sensor............ 172 Checking signal cable, oil temperature sensor....... 192 Checking signal cable, seawater pressure sensor. 174 Checking signal cable, water switch, fuel filter....... 161 Checking supply cable, air inlet pressure sensor... 179 Checking supply cable, coolant pressure sensor... 155 Checking supply cable, coolant switch................... 182 Checking supply cable, crankcase pressure sensor..................................................................... 184 Checking supply cable, fuel pressure sensor......... 157

Checking the coolant temperature sensor.............. Checking the crankcase pressure sensor.............. Checking the external stop voltage potential.......... Checking the fuel pressure sensor......................... Checking the injector coils...................................... Checking the intake manifold temperature sensor.

182 185 195 158 168 171

Checking Checking the the oil oil level level sensor.................................. switch.................................. 166 165 Checking the oil pressure sensor........................... 173 Checking the oil temperature sensor.............. 190, 190, 193 Checking the piston cooling pressure sensor......... 177 Checking the pre-start relay................................... 194 Checking the seawater pressure sensor................ 175 Checking the starter motor solenoid....................... 194 Checking the wastegate valve................................ 159 Checking the water in fuel switch, fuel filter........... 162 Component description............................................ 42 Component location................................................. 32 D Design and Function.......................................... 32, 32, 58 E Engine Protection Map............................................... 9 F Fault Codes.............................................................. 74 Fault Tracing............................................................ 74 Function fault............................................................ 72 G General......................................................... 2, 32, 32, 197 I Index....................................................................... 199 Injector trim............................................................. 167 M Measurements........................................................ 155 MID 128, PID 100 Engine oil pressure..................... 86 MID 128, PID 105 Intake manifold temperature....... 89 MID 128, PID 106 Air inlet pressure......................... 92 MID 128, PID 110 Engine coolant temperature........ 95 MID 128, PID 111 Coolant level............................... 98 MID 128, PID 153 Crankcase pressure.................. 100 MID 128, PID 158 ECU battery potential................ 103 MID 128, PID 163, Transmission range attained... 104 MID 128, PID 173 Exhaust gas temperature.......... 105 MID 128, PID 175 Engine oil temperature...... 107, 107, 110 MID 128, PID 190 Engine speed............................ 113 MID 128, PID 20, Extended Range Engine Coolant Pressure...................................................... 74 MID 128, PID 94 Fuel Delivery Pressure................. 76 MID 128, PID 97 Water in fuel indicator................... 79 MID 128, PID 98 Engine oil level.............................. 83 MID 128, PPID 117 Engine protection status......... 122 MID 128, PPID 132 Throttle Calibrated Position.... 123

Checking supply cable, oil level switch.................. 164 Checking supply cable, oil pressure sensor........... 172 Checking supply cable, seawater pressure sensor  174 Checking supply cable, water switch, fuel filter...... 160 Checking the air inlet pressure sensor................... 179 Checking the coolant pressure sensor................... 156 Checking the coolant switch................................... 183 47700583

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MID 128, PSID 112 Exhaust Manifold Water  Temperature Tempe rature Sensor #1..... #1........... ............. ............. ............. ............. .......... .... 146 MID 128, PSID 216 Data Link, MID187.................. 148 MID 128, SID 1/2/3/4/5/6 1/2/3/4/5/6 Injector # 1-6........... 1-6.................. ....... 126 MID 128, SID 21 Engine position...... position............. ............. ............ ........ .. 130 MID 128, SID 211 Sensor Supply Voltage #2 (+5 V DC)......... DC)............... ............. ............. ............. ............. ............ ............. ............. ........... ..... 81 MID 128, SID 22 Timing Timing sen sensor, sor, crank...... crank............. ............ ..... 133 MID 128, SID 231 231 SAE J1939 data data link......... link............... ........ .. 145 MID 128, SID 232 5 V supply......... supply................ ............. ............ ........... ..... 142 MID 128, SID 240 Program memory........ memory.............. ............ ........ .. 143 MID 128, SID 253 253 Calibration Calibration memory memory EEPROM EEPROM ... 82 MID 128, SID 254 Controller Controller 1............... 1...................... ............. ......... ... 144 MID 128, SID 32, Wastegate output output driver.......... driver............. ... 137 MID 128, SID SID 89 Air Compress Compressor or Actua Actuator tor Circuit. Circuit. 140 MID 158, PSID 1, Primary battery circuit................ 149 MID 158, PSID 2, Secondary Secondary battery circuit...... circuit........... ..... 150 MID 158, PSID 4, 30 supply fuse..... fuse........... ............. ............. ......... ... 151 MID 158, PSID PSID 5, EMS supply supply fuse......... fuse................ ............. ........ 152 MID 158, PSID 6, Extra supply fuse........ fuse.............. ............. ......... .. 154 R Repair Instru Instructions ctions....... ............. ............ ............. ............. ............. ............. ............ ...... 61 Repair instructions...................................................... 3 S Safety Information... Information......... ............ ............. ............. ............. ............. ............ ........... ..... 26 Safety Instructions.................................................... 26 Special Service Tools............................................... 30 Specifications, Electrical............................................. 5 Switches and Senders................................................ 5 W Wiring Diagrams..................................................... 196

MID 128, PPID 267, Sea water pressure............... 124 MID 128, PPID 3 Starter Output............................. 114 MID 128, PPID 6 Key off input sensor.................... 115 MID 128, PPID 8 Piston Cooling Oil Pressure 117, 117, 120 MID 128, PPID 98 Engine sync acknowledge........ 121

201

202  

References Reference s to Service Bulletins Group No.

Date

Refers to

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............................................................................................................................................................................. ............................................................................................................................................................................. .............................................................................................................................................................................

203

 

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