Volvo Penta D9 D11 D12 D13 D16 Marine Engines (EMS 2) Group 30 Electrical System Workshop Manual PDF

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 ........................................................................ 10

Special tools 08-2 Special Service Tools ................................................................... 15

General, Complete Vehicle Software 30-0 General ........................................................................................... 17 Design and Function ......................................................................... 17 30-2 Fault Tracing ................................................................................. 59 Fault Codes ........................................................................................ 59 Measurements .................................................................................. 140

Cables and fuses 37-0 Wiring Diagrams ......................................................................... 181

Miscellaneous 39-0 General ......................................................................................... 182 Index ......................................................................................................... 187 References to Service Bulletins ............................................................ 189

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1

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 Specifications.

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

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 product data which was available up to the date on which the manual was printed. New working methods and significant changes introduced to the product after this date are communicated in the form of Service 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.

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: •

Maintenance and service intervals recommended by Volvo Penta must be complied with.

•

Only spare parts approved by Volvo Penta may be used.

•

Service on injection pumps, pump settings and injectors must always be carried out by an authorized Volvo Penta workshop.

•

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

•

No changes to the exhaust pipe and engine air inlet duct installations may be made.

•

No warranty seals (where 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 adjusted be correctly set up and that only Volvo Penta Original Parts are used. The 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.

Warning symbols that occur in the service manual.

For significance, refer to Safety Information.

DANGER! WARNING! CAUTION! IMPORTANT!, NOTE! 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 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.

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.

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 wash residues etc. are correctly properly for destruction.

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 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 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

0.5–4.5 V

Working range, temperature

-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

0.5–4.5 V

Working range, temperature

-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

0.5–4.5 V

Working range, temperature

-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 All versions of Engine Protection Maps, are to be found at the Volvo Penta Sales Support Tool, Technical data for concerned engine type.

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05-1 Safety Instructions

05-1 Safety Instructions Safety Information This workshop manual contains repair instructions, descriptions and technical data for products or product drawings from Volvo Penta. Check that you have the correct workshop manual.

Read the safety information below and the section About this Workshop manual and Repair instructions carefully before beginning any work with repairs or service.

!

In the workshop manual and on the product, this symbol is used to call your attention to the fact that this is safety information. Always read such information very carefully.

Warning 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 make you aware of something that may cause minor damage or a minor malfunction to the product or property.

NOTICE! Is used to make you aware of important information that will facilitate the work or operation in progress.

This symbol is used on certain functions 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 informs you that supplemental information needs to be read. And where necessary information can be found.

This symbol is used when a VODIA computer is needed, either for troubleshooting, testing or programming.

A compilation of safety precautions that must be taken and risks which you must be aware of is presented in the following pages.

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05-1 Safety Instructions

!

Immobilize the engine by turning off the power supply with the main switch(es) and lock it (them) in the off position before starting work.

Place a warning notice at the main switch.

!

Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant may spray out and the system can lose pressure. 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 while the engine is hot.

!

As a general rule, all service operations must be carried out with the motor stopped. However, some work, such as adjustments, will require the engine to be running. Approaching a running engine is a safety risk. Remember that loose clothing and long hair can fasten in rotating parts and cause serious personal injury.

!

Hot oil can cause burn injuries. Avoid exposing your skin to hot oil. Make sure that the lubrication system is not under pressure before any work is begun. Never start or run an engine without the oil filler cap in place. Hot oil under pressure can spray out.

!

Be aware of hot surfaces (exhaust pipes, turbocharger, charge air pipe, starting heaters, etc.) and hot liquids in supply lines and hoses on an engine that is running or has just stopped.

A careless movement or a dropped tool may, in the worst case, result in personal injury when working in the vicinity of a running engine.

!

Never start the engine without the air filter in place. 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 starting the engine.

!

Make sure that all warning and information decals on the product are always visible.

Replace decals that have been damaged or painted over.

!

Only start the engine if the surrounding ventilation is satisfactory. When operating in a confined space, exhaust fumes and crankcase gases must be led away from the engine compartment or workshop area.

!

Avoid getting oil on the skin! Protracted or repeated exposure to oil can cause skin to become dry. Irritation, dryness, eczema and other skin problems may then result. Used oil is more dangerous than fresh oil from a health aspect. Use protective gloves and avoid oilsoaked clothes and rags. Wash regularly, especially before eating. Use suitable protective creams to counteract skin dryness 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 health hazards. Carefully read the instructions on the product packaging! Always follow the safety directions for a product, e.g. with regard to use of protective mask, glasses, gloves, etc. Make sure that other personnel are not exposed to substances that are health hazards. Ensure good ventilation. Handle used and leftover chemicals in the prescribed manner.

!

Turn off the engine and disconnect the power at the main switch(es) before starting work on the electrical system.

!

Only make connection adjustments with the engine switched off.

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05-1 Safety Instructions

!

Always wear protective goggles if there is a risk of splinters, sparks and splashes from acid or other chemicals. Your eyes are extremely sensitive, injury to them could result in 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 seacock/cooling water inlet valve before starting work on the cooling system.

!

All fuels, and many chemicals, are flammable.

Never allow open flames or electrical sparks in the their vicinity. Gasoline, certain solvents and hydrogen from batteries are extremely flammable and explosive in the right concentration in air. No smoking! Ensure 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 rags soaked in oil or fuel and used fuel and oil filters are stored safely. Oilsoaked rags may ignite spontaneously in certain conditions. Used fuel and oil filters are environmentally hazardous waste and must be taken to an approved waste management facility for correct handling, as must any used lubricating oil, contaminated fuel, paint residue, solvents, degreasers and wash residue.

!

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

!

Never work alone when dismantling heavy components, even when using lifting equipment such as lifting devices with lockable blocks. Two people are usually required when using a lifting device; one to operate the lifting device and the other to make sure the components do not collide with objects and suffer damage during the hoist.

!

Use the loops on the engine when lifting it.

Always check that the hoisting equipment is in good condition and has the capacity to lift the engine (engine weight including gearbox and any auxiliary equipment installed). The engine must be lifted with a properly adjusted lifting boom to ensure safe handling and avoid damage to components fitted to the top of the engine. All chains or wires must run parallel to each other and be as perpendicular to the engine as possible. If the engine has equipment fitted that alters its center of gravity, special lifting devices may be required to achieve the correct balance for safe handling. Never carry out any work on an engine that is only suspended by lifting equipment.

Do not touch the connections during a starting attempt. Spark hazard! Do not lean over batteries.

!

12

Never mistake the positive (+) for the negative (-) battery pole when installing batteries.

Incorrect pole connections can result in serious damage to electrical equipment. Refer to the wiring diagram.

Always wear protective goggles when charging or handling the batteries. The battery electrolyte contains sulfuric acid which is highly corrosive.

Rinse immediately with plenty of water and soap if battery electrolyte comes into contact with unprotected skin. If you get battery acid in your eyes, flush at once with a generous amount of water, and get medical assistance at once.

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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 operated in areas where there are explosive materials or gases.

!

Take extreme care when searching for fuel system leaks and testing fuel injector nozzles.

Wear safety goggles. The jet from a nozzle is under very high pressure and has great penetration power. Fuel can penetrate deep into body tissue and cause severe injury. There is a risk of blood poisoning (septicemia).

!

Only use fuels and lubricating oils as recommended by Volvo Penta. Refer to the operator's manual for the product concerned.

Using fuels that are of a lower grade may damage the engine, the injection pump and the injectors. In the case of diesel engines, lowquality fuel may cause the control rod to stick and the engine to overrev with the risk of engine damage and personal injury as a result. Lowquality fuel and oils may lead to higher service, maintenance and repair costs.

!

Never use a high-pressure washer to clean the engine.

Pay attention to the following when using a highpressure washer on components other than the actual engine: Never aim the water jet at seals, rubber hoses or electrical components.

!

Under no circumstances may fuel pipes be bent or straightened. Cracks may occur. Damaged pipes must be replaced.

!

When overhauling an engine, perform leakage and functional checks as necessary.

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05-1 Safety Instructions

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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

1

3

4

5

75

8856

2

P0006701

885675 Break-out cable

p0008375

p0005125

88820047 VODIA, diagnostic tool Complete tool.

Used for taking readings.

9990014 Break-out cable Used for EMS2.

9998482 Measuring tool Measuring tool for control unit connector.

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

9998699 Break-out box Used for taking readings.

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

Adapter cable for sensor testing.

88890074 Multimeter

P0008793

p0005128

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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 Sensor, coolant level 2 Sensor, crankcase pressure 3 Stop button and fuses 4 Sensor, combined air inlet pressure and intake manifold temperature 5 Sensor, combined oil pressure and oil temperature (engine) 6 DC/DC-converter 7 Sensor, fuel pressure 8 Sensor, water in fuel 9 Sensor, coolant temperature 10 Switch, oil level (optional) 11 Engine control unit (EMS2) 12 Sensor, camshaft position 13 Sensor, flywheel position

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30-0 General

Location of sensors, D9 classified

BROKEN

TESER ERIW NEKORB

REWOP

NRG

28 1 28 2 2 3 24 2 NWODTUHS LS RO TINU 2 2 2 6638183 RS FS 1T ETAD .TCAFUNAM 2 AS 612060 BS 2 2 66 DEEPSREVO SO 56 2 2 .PMET TSUAHXE 21 6S 2 2 .PMET LIO .GNE 11 5S 2 2 .SSERP TNALOOC 01 4S 2 2 .SSERP LIO .GNE 9 3S 2 2 .SSERP LIO RAEG 8 2S 2 2 .PMET TNALOOC 7 1S MRALA DEEPSREVO DER VF 4S ROF TCETED NUR WLY SS 3S,2S ROF TCETED NUR NRG 6S 6S 5S 5S 4S 4S 3S 3S !LOOT CITSALP ESU 2S 2S 1S 1S TSET DEEPSREVO

WIRE

ALARMS SHUTDOWN

12

18 11

19

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5

4 2

3

1

6

7

8

10

9

13 14

17

15

16

P0017067

30-0 General

Location of sensors, D9 classified 1 Sensor, coolant level 2 Sensor, crankcase pressure 3 Aux stop button 4 Sensor, combined air inlet pressure and intake manifold temperature 5 Sensor, combined oil pressure and oil temperature (engine) 6 Power Module 7 Sensor, fuel pressure 8 Sensor, water in fuel 9 Sensor, coolant temperature 10 Switch, oil level (optional) 11 Engine control unit (EMS2) 12 SDU (Shutdown Unit) 13 Sensor, camshaft position 14 Sensor, flywheel position 15 Sensor, freshwater pressure 16 Sensor, piston cooling pressure 17 Sensor, seawater pressure 18 Sensor, exhaust temperature

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30-0 General Location of sensors, D11

P0018112

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30-0 General

Location of Sensors, D11 1 Sensor, crankcase pressure 2 Sensor, coolant level 3 Sensor, piston cooling pressure 4 Sensor, fuel pressure 5 Sensor, combined oil pressure / oil temperature 6 Sensor, flywheel position 7 Sensor, air inlet pressure / intake manifold temperature 8 Sensor, seawater pressure (D11B3-A MP, D11B4-A MP) 9 Sensor, camshaft position 10 Sensor, freshwater pressure (D11B3-A MP, D11B4-A MP) 11 Sensor, coolant temperature 12 Sensor, engine oil level

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30-0 General Location of sensors, D13

P0019225

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30-0 General

Location of Sensors, D13 1 Seawater pressure sensor (D13B-C/D/E/F/L/M/N, D13C3-A, D13C4-A only) 2 Fuel pressure sensor 3 Charge pressure sensor / Charge air temperature sensor 4 a Auxiliary stop (D13B-A/B/G/H/J/K, D13C1-A, D13C2-A 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) b Exhaust temperature alarm(2) (D13B-A/B/G/H/J/K, D13C1-A, D13C2-A only) 6 Level sensor for water separator (D13B-A/B/G/H/J/K, D13C1-A, D13C2-A only) 7 Engine control unit (EMS2) 8 Oil level and oil temperature sensor 9 Crankcase sensor 10 Oil pressure sensor 11 Coolant level monitor 12 Tachometer sensor, flywheel 13 Rpm sensor, camshaft 14 Coolant temperature sensor 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

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Location of Sensors, D16 1 Switch, coolant level 2 Power Module 3 Sensor, boost pressure and boost temperature 4 Sensor, fuel pressure 5 Sensor, coolant temperature 6 Sensor, water in fuel 7 Sensor, crankcase pressure 8 Sensor, oil temperature and oil level 9 Sensor, oil pressure 10 Sensor, seawater pressure 11 Emergency stop button 12 Tachometer sensor, flywheel 13 Rpm sensor, camshaft 14 Switch, piston cooling 15 Sensor, freshwater pressure

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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 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) 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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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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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 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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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 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 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 of a non-linear resistor, whose resistance varies with engine oil temperature.

The resistance falls as the oil temperature rises.

The pressure 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 back on the right side of the engine and is identical with the engine speed sensor.

The sensor is inductive. The sensor reads a toothed wheel with seven teeth (six of which 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 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

P0017174

1

NOTICE! When changing from a normally open (NO) 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.

New model: Blue label (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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Shutdown Unit (SDU) 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 to EMS2 in case of shutdown.

P0011559

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 becomes too high.

Oil pressure switch, reverse gear (S2) (D9 MH, D13 MH, D16 MH)

P0017122

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 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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30-0 General 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

38

T. P. F. I. A.

Inlet from fuel tank (Tank) Outlet to feed pump (Pump) Inlet from fuel filters (Filters) Outlet to unit Injectors (Injectors) Cable harness (Signal from engine protection unit)

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SDU adjustments

1 = Channel On / Off jumpers P0018655

Channel set-up 1 Locate the channel on/off jumper pins (1) on the SDU card.

2 Disable all the S1–S6 channels before configuring run detection and overspeed. = Channel disabled ON

OFF

Channel Switch S1.

Coolant temperature S2.

Oil pressure, reverse gear(1) S3.

Oil pressure, engine(1) S4.

= Channel enabled ON

Switches/sensors, engine protection system The respective switch or sensor shuts down the engine at the preset values found at section Engine Protection Map.

S5.

S6.

Coolant Pressure(2) Oil temperature, engine Exhaust temperature

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.

NOTICE! Frequency (Hz) = rpm x pulses/revolution / 60 These values are found at section Engine Protection Map.

1

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

6

2

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

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 “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

Connect a sinusoidal frequency generator (G) to the 65, 66 inputs.

4

Connect 88890074 Multimeter in parallel with the frequency generator to measure the frequency.

7

Ramp the frequency from 0 Hz to the run detection level to make sure that correct limit is configured.

5

Set the frequency generator to the run detection frequency.

8

Make the same procedure for the S4 run detection (configure “B”). The S4 LED (3) color is yellow.

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P0018658

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

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

1

Connect the sinusoidal frequency generator to the 65, 66 inputs.

5

Set the frequency generator to 0 Hz and then push the shutdown reset button (R).

2

Connect 88890074 Multimeter in parallel with the frequency generator (G) to measure the frequency.

6

Ramp the frequency from 0 Hz to the overspeed limit to make sure that correct limit is configured.

7

If the S6 channel is used, proceed with the exhaust temperature configuration.

8

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

3

Set the frequency generator to the overspeed frequency seen in the table on the next page.

4

If the red LED (2) is not lit: Turn “C” counterclockwise until the red LED is lit.

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P0018659

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

1 Calibrate a variable resistor to a shutdown temperature value according to the table.

2 Connect the configured resistor to the S6, 2 inputs.

Temperature 500 °C / 932 °F 550 °C / 1022 °F 600 °C / 1112 °F 650 °C / 1202 °F 700 °C / 1292 °F

PT200 resistance 562 Ω 595 Ω 628 Ω 659 Ω 690 Ω

3 Locate the variable resistor “D” and calibrate it until the S6 LED (5) is lit. – Turn counterclockwise to increase the shutdown limit. – Turn clockwise to decrease the limit.

4 Reset with the shutdown reset button (R).

Calibrate once more and then reset.

5 Enable the channels S1–S6 according to 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.

The system has been developed by Volvo Penta and includes fuel control and diagnostic function.

B

I

* EMS= ”Electronic Management System”.

J

Control unit

E

K

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

F

L

The processor receives continuous information about:

C

ECU

D

• Engine speed P0007162

O

N

M

Engine Control Unit (ECU)

• Throttle opening • Oil pressure

A

Engine speed

• Oil temperature

B

Throttle opening

• Crankcase pressure

C

Oil pressure/-temperature

• Air inlet pressure / intake manifold temperature

D

Air inlet pressure / intake manifold temperature

E

Crankcase pressure

F

Coolant temperature

G Diagnostics H

Camshaft position

I

Fuel alarm, water in fuel

J

Fuel pressure

K

Coolant level/oil level

L

Piston cooling pressure

M Checking the wastegate control (D12) N

Fuel volume

• Fuel pressure • Fuel alarm, ”water in fuel” • Camshaft position • 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.

O Injection advance

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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 the engine control unit discovers that cylinder 1 is 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 tries again. It will take a bit longer time to start the engine, 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 disconnect the current with the main switches when an engine is running.

•

Never undo a battery cable when the engine is running.

•

Turn the main switches off or disconnect the battery cables during quick charging of the batteries.

NOTICE! During normal trickle charging, it is not necessary to turn the main switches off.

•

Only batteries may be used for start help. A help start device can produce a very high voltage and damage the control unit and other electronics.

•

If damage is discovered in a cable harness 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 connector is disconnected from a sensor, be very careful to avoid allowing the contact pins to come into contact with oil, water or dirt.

Electrical Welding 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.

Check all connectors visually Check the following:

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

•

Look for oxidation, which can impair contact in connectors.

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

•

Check that terminals are undamaged, that 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 that there is good mechanical contact in the connector. Use a loose pin to check this.

IMPORTANT! The multi-pin connectors for the engine control unit must only be checked with gauge 9998482.

Carefully insert gauge 9998482 into the multipin 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 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 which are relevant to the function. Start off with the most probable cable harness in the circuit.

Check the following:

•

If possible, shake the cables and pull the connectors during measurement to discover whether the cable harness is damaged.

•

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

•

Check the function of the secondary locking.

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•

Disconnect the relevant connector at each end of the cable harness.

•

Use multimeter 9812519 to measure the resistance between the ends of the cable.

Nominal value close to 0 Ω.

•

If possible, shake the cables and pull the connectors during measurement to discover whether the cable harness is damaged.

•

Check the next cable harness in the wiring 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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30-0 General 4 1 2

999

9 869

7

6 5 4 3 2 1

10 9

8

17 24

31 38

49 48

47 46

45 44

43

42 41

40 39

37 36

35 34

33 32

30 29

28 27

26 25

23 22

21 20

19 18

16 15

14 13

12 11

Connect the engine control unit connector to the brakeout cable 9990014 (1). Connect the brakeout cable 9990014 to the engine control unit (2).

All pins from the engine control unit is accessible in the measurebox 9998699.

52 51

50

56 55

54 53

62 61

60 59

58 57

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

47700583 08-2019 © AB VOLVO PENTA

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.

49

30-0 General

Checking the charging system

Fault tracing the charging system

Special Tools: 9812519.

Battery

Generally about alternators: 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+.

1 Check that all connectors at the battery is correctly assembled.

When the engine is started an excitation current is needed to “wake up” the alternator.

NOTICE! It is the consumers (batteries included) which decides the output current from the alternator.

Measurements

2 Check the conditions of the cables to the battery.

3 Check the water level in the battery.

4 Check, if possible, the specific gravity of all cells. when no charge 1 Check the alternator belt tension.

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

3 Check the condition of all cables in the charging system.

4 Check the brushes length and condition.

5 Change, if possible, the regulator.

1 Engine off.

when undercharge

2 Use multimeter 9812519 to do a voltage measurement over the battery. The nominal voltage over a full loaded battery is approx.

12.6V or 25.2V.

1 Check the alternator belt tension.

3 Engine on. Run at 1500 rpm.

4 Use multimeter 9812519 to do a voltage 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 that all connectors at the alternator and at the battery is correctly assembled.

3 Check the condition of all cables in the charging system.

4 Check the brushes length and condition.

5 Change, if possible, the regulator. when overcharge 1 Change, if possible, the regulator.

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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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51

30-0 General Pull out the brushes.

5

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

8 04

4

P0008406

5mm P0008407

Alternator brush installation 1

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

P0008408

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30-0 General

Alternator faulttracing Valid for alternator 20409228.

• NOTICE! Cut the current with the main switch.

• 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.

• Switch the probe points and check that there is no short circuit.

• NOTICE! If a regulator fault is suspected install a new regulator and test 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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30-0 General

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 pin 30), the engine control unit pin A58 receives an activation signal from the PCU via pin 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.

IMPORTANT! The system must be disconnected from system voltage when the engine control unit connectors are disconnected or connected.

2 Remove the two connectors from the engine control unit. Turn the locking arm down at the same time as the connector is pulled outwards.

3 If the new engine control unit has recently been programmed: Start the engine and check if there are any faults.

P0008530

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30-0 General

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 site, http://www.vppn.com 2 Choose ”Vodia” in the left-hand menu.

3 Choose ”ECU Programming” in the left-hand menu.

4 Follow the instructions under ”Download software”. Choose the control units to be re-programmed and click the ”Download” button. The software for the selected control units is now downloaded to the PDA (Personal Digital Assistant).

5 Take a look under ”Settings”, ”Software information” in Vodia to check that the software has been downloaded.

6 Connect the Vodia to the engine to be programmed.

7 Start with the engine control unit. Select ”Engine with mounting and equipment” in the Vodia menu.

Select ”MID 128 Control unit, programming”. Vodia will guide you through the entire programming process.

8 The next control unit is the vehicle control unit, PCU (Powertrain Control Unit). Select ”Electrical 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 control unit to be programmed is the HCU (helm station control unit). Select ”Electrical 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! 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 site, http://www.vppn.com 11 Choose ”Vodia” in the left-hand menu.

12 Choose ” Report software” in the left-hand menu.

13 Follow the instructions for ”Report software/parameter”. Click ”Report software/parameter”.

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30-0 General

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 both part numbers available.

2 Log in to Volvo Penta Partner Networks web site, http://www.vppn.com 3 Choose ”Vodia” in the left-hand menu.

4 Choose ”Conversion kit” in the left-hand menu. A new page, ”Conversion kit / Accessory kit”, opens up.

5 Click the text ”Available conversions kits” which is shown in bold face. Follow the instructions described in the window.

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

7 Volvo Penta’s computer system is now updated. This may take a minute or so before a confirmation is sent back.

8 Programming of the control unit can now be done, please refer to “Programming the Control Unit”.

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Function fault Fault code information •

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

•

PID (“Parameter Indication Description”): The PID consists of a number that designates a parameter (value) to which the fault code relates (oil pressure, for example).

•

PSID (“Proprietary SID”) The same as the SID, but this is a Volvo-specific component.

•

•

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

FMI (“Failure Mode Identifier”): 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

”Electrical fault”

Voltage below normal or shorted to lower voltage

5

”Electrical fault”

Current below normal or open circuit.

6

”Electrical fault”

Current above normal or short circuit to battery negative

7

”Mechanical fault”

Mechanical system not responding properly

8

”Mechanical or electrical fault”

Abnormal frequency, pulse width or period

9

”Communication fault”

Abnormal update rate

10

”Mechanical or electrical fault”

Abnormally large variations

11

”Unknown fault”

Unidentifiable error

12

”Component fault”

Faulty device or component

13

”Faulty calibration”

Calibration value out of range

14

”Unknown fault”

Special instructions

15

”Unknown fault”

Reserved for future use.

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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30-0 General

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

If there is an active / inactive fault code Remove the connector from the sensor. Check that there is no oxidation and that the connector pins are not damaged. If there is a fault, please refer to ”Fault Tracing the Cables and Connectors”.

NOTICE! Some fault codes become inactive when the engine is stopped. Start the engine to check whether the fault code is still inactive with the engine running.

•

After an action with the connector Put the connector* back. Check if the fault code becomes inactive. If the fault remains, measure the cables and sensors to check them, as instructed.

NOTICE! * No grease in the connector.

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.

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

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

NOTICE! If the engine control unit has not been identified, it can not be programmed.

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

Shut the system off with the AUX stop button.

The starter motor is activated with the ignition on.

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.

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.

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30-2 Fault Tracing

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 •

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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 level and the quality of the coolant.

2 Check that no leakage occurs.

3 Check the coolant circulation pump.

4 Check the sensor by control measuring the coolant pressure.

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

Faulty sensor/Fault in sensor circuit •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 B20 exceeds 4.95 volts.

Possible reason:

Suitable action:

•

Open circuit in the sensor negative cable.

•

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

•

Faulty sensor

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

2 Check contact pressure in socket 18 in engine connector B. 3 Check the sensor.

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30-2 Fault Tracing

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

Faulty sensor/Fault in sensor circuit

Fault indication:

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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:

Suitable action:

•

Open circuit in the sensor 5 V supply cable.

•

Open circuit in sensor signal cable.

•

Short circuit between sensor signal cable and battery negative to coolant pressure sensor.

•

Faulty sensor.

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

2 Check contact pressure in socket 18 in engine connector B. 3 Check the sensor.

Circuit description

20 GN/SB (+)17 R SB (-)18 b EMS 2

2

a

1 4

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.

P0007184

a

Coolant Pressure

b

Connector B (Gray)

Measurements Checking supply cable, coolant pressure sensor Checking negative cable, coolant pressure sensor Checking signal cable, coolant pressure sensor Checking the coolant pressure sensor

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30-2 Fault Tracing

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.

•

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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 Check fuel level.

2 Open the fuel taps and check that no leakage occurs.

3 Check the fuel hoses to ensure that none have been crushed or kinked.

4 Change the fuel filters (primary and secondary filter).

5 Check the sensor by checking the fuel pressure.

6 Check the overflow valve and change it if necessary.

7 Check the feed pump.

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

Faulty sensor/Fault in sensor circuit.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between the sensor signal cable and the sensor 5 V supply cable or battery voltage.

•

Open circuit in the sensor negative cable.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in socket 18 in engine connector B. 3 Check sensor.

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30-2 Fault Tracing

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

Faulty sensor/Fault in sensor circuit.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 circuit in 5 V supply cable.

•

Open circuit in signal cable.

•

Short circuit between the sensor signal cable and the sensor negative cable.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in sockets 16 and 17 in engine connector B. 3 Check the sensor.

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

Fuel pressure too low.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

Symptom:

None

Preconditions:

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

Conditions for fault code:

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

Suitable action:

1 Check fuel level.

2 Open the fuel taps and check that no leakage occurs.

3 Check the fuel hoses to ensure that none have been crushed or kinked.

4 Change the fuel filters (primary and secondary filter).

5 Check the sensor by checking the fuel pressure.

6 Check the overflow valve and change it if necessary.

7 Check the feed pump.

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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

Component specification

V

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 normal atmospheric pressure

Output voltage Fuel pressure

Measurements Checking supply cable, fuel pressure sensor Checking negative cable, fuel pressure sensor Checking signal cable, fuel pressure sensor Checking the fuel pressure sensor

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30-2 Fault Tracing

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.

•

Warning is displayed in the tachometer/display.

•

Water-in-fuel warning flashes in the alarm panel.

Symptom:

None

Preconditions:

Water in Fuel

Conditions for fault code:

Water in the fuel trap has been detected.

Possible reason:

Suitable action:

•

Water in fuel trap.

•

Short circuit between the yellow cable of the water in fuel switch and battery negative.

1 Empty the water in the fuel trap.

2 Check the cables to the water in fuel switch.

3 Check the water in fuel switch.

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

Faulty sensor/Faulty switch circuit •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 harness between water in fuel switch and EMS 2.

P0007193

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30-2 Fault Tracing

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. 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.

R/BL SB Y B A C

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

Y

P0007194

a

Connector B Color: GrAy

D9 CC

D11, D13 a R SB Y

a

SB

B AC Y

Y SB R

C AB Y

R /BL

SB 10

8

EMS2

SB

R /BL

Y

R /BL 4(+)

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 Checking negative cable, water switch, fuel filter Checking signal cable, water switch, fuel filter Checking the water in fuel switch, fuel filter

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30-2 Fault Tracing

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 circuited to battery voltage

•

Faulty sensor

1 Check the cables between the sensor and the engine ECU 2 Check the sensor

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 circuited to battery negative

•

Faulty sensor

1 Check all cables and connectors between the sensor and the engine ECU 2 Check the sensor

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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:

The engine cannot be started.

Suitable action:

1 Reprogram engine ECU.

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30-2 Fault Tracing

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.

•

Warning is displayed in the tachometer/display.

•

Oil level warning flashes in alarm panel + audible warning.

Symptom:

None

Preconditions:

Oil level too low.

Suitable action:

1 Check the oil level in the engine.

2 Check that no leakage occurs.

3 Check the sensor.

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

Faulty sensor/Fault in sensor circuit •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

Symptom:

None

Preconditions:

Current below normal or open circuit.

Possible reason: Suitable action:

•

Open circuit in the sensor 5 V supply cable.

•

Faulty sensor.

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

2 Level sensor: Check contact pressure in sockets 3 and 4 in engine connector B. 3 Check the sensor.

D9, D11, D12

68

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

1

4

c 2 3

4 GN/W

a

a Connector A b Connector B

31

GR/OR

c Oil temperature and level sensor

EMS2 P0008588

D13

P0010638

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30-2 Fault Tracing

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

Oil level monitor

b

Connector B

D11

a (-)10 (+)57,60

SB R/BL a ConnectorA

2 1

b

3 26

c

b Connector B c Oil level monitor

GN/W

P0008587

Measurements Checking supply cable, oil level switch Checking negative cable, oil level switch Checking the oil level switch Checking the oil level sensor

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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.

•

Warning is displayed in the tachometer/display.

•

Oil pressure warning flashes in alarm panel + audible warning.

Symptom:

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 level in the engine and the oil quality.

2 Check that no leakage occurs.

3 Check that the oil filters are not blocked. Change oil filters and engine oil.

4 Check the sensor by checking the engine oil pressure.

5 Check if the safety valve or the pressure relief valve is stuck open.

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

Faulty sensor/Fault in sensor circuit.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between the sensor signal cable and the sensor 5 V supply cable or battery voltage.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check the sensor.

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

Faulty sensor/Fault in sensor circuit.

Fault indication:

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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:

Suitable action:

•

Open circuit in 5 V supply cable.

•

Open circuit in signal cable.

•

Short circuit between the sensor signal cable and the sensor 5 V supply cable or battery voltage.

•

Short circuit between the sensor signal cable and the sensor negative cable.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in socket 11, engine connector B, and socket 7 in engine connector A. 3 Check the sensor.

D9, D11, D12 a (+)7 R (-)11 SB 31

Circuit description c 4

1 3 P2

GR / OR

EMS2 b 11

BL / OR

P0007206

a

Connector A

b

Connector B

c

Oil pressure/temperature sensor

D13 b

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 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 11

BL / OR

EMS2 P0017175

4

a

(+)7 (-)11

1

P2

R SB

4

c

EMS2 b

1

P2

11 BL / OR P0017176

P0017175

a

Oil pressure sensor

b

Connector B

72

a

Connector A

b

Connector B

c

Oil pressure sensor

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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 normal atmospheric pressure

kPa

P0007192

V kPa

Output voltage Oil Pressure

Measurements Checking supply cable, oil pressure sensor Checking negative cable, coolant pressure sensor Checking signal cable, oil pressure sensor Checking the oil pressure sensor

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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.

•

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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 temperature and coolant temperature are normal.

2 Check the sensor.

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

Faulty sensor/Fault in sensor circuit.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between the sensor signal cable and the sensor negative cable.

•

Faulty sensor

1 Check cables and connectors between the sensor and engine control unit.

2 Check the sensor.

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

Faulty sensor/Fault in sensor circuit.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between the sensor signal cable and the sensor 5 V supply cable or battery voltage.

•

Open circuit in signal cable.

•

Faulty sensor

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in socket 47 in engine connector A. 3 Check the sensor.

D9, D12

D11, D13, D16

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D9, D12

Circuit description

a

ConnectorA

b

Air inlet pressure/intake manifold 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 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 inlet pressure/intake manifold temperature

Measurements Checking negative cable, intake manifold temperature sensor Checking signal cable, intake manifold temperature sensor Checking the intake manifold temperature sensor

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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.

•

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

Symptom:

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 compressor unit. The turbocharger must comply with the specification for the engine.

2 Check the sensor by checking the air inlet pressure.

3 Check the wastegate valve function.

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

Faulty sensor/Fault in sensor circuit.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between sensor signal cable and sensor supply cable or battery voltage

•

Open circuit in the sensor negative cable.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in socket 11 in engine connector B. 3 Check the sensor.

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

Faulty sensor/Fault in sensor circuit.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 circuit in 5 V supply cable.

•

Open circuit in signal cable.

•

Short circuit between the sensor power 5 V supply cable and the sensor negative cable.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in sockets 22 and 7 in engine connector A. 3 Check the sensor.

D9. D12

78

D11, D13, D16

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D9, D12

a

ConnectorA Color: Black

b

Air inlet pressure/intake manifold temperature

D11, D13, D16

Circuit description 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 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

a

ConnectorA

b

Air inlet pressure/intake manifold temperature

c

Joint

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) 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 Checking signal cable, air inlet pressure sensor Checking the air inlet pressure sensor Checking supply cable, air inlet pressure sensor

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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 •

Warning is displayed in the tachometer/display.

•

The warning symbol in the alarm panel flashes red. The coolant 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:

•

Low coolant level.

•

Blocked seawater filter

•

Worn impeller in seawater pump

•

Pinched, leaking or blocked hose on the suction side (seawater).

•

Defective thermostat

•

Blocked heat exchanger

•

Poor flow in the cooling system

•

Worn coolant pump

•

Defective pressure cap, expansion tank.

•

Defective temperature sensor, coolant.

1 Check the coolant level.

2 Check that the system does not leak.

3 Check that the seawater filter is not blocked.

4 Remove the reverse gear oil cooler end plate and check whether the oil cooler is clogged.

5 Check the impeller in the seawater pump.

6 Check the coolant temperature sensor.

7 Clean the heat exchanger in the cooling system.

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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.

•

Warning is displayed in the tachometer/display.

•

Orange lamp flashing in alarm panel.

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 B27 lower than 0.07 volts.

Possible reason:

Suitable action:

•

Short circuit between the sensor signal cable and the sensor negative cable.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check the sensor.

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

Faulty sensor/Fault in sensor circuit.

•

Warning is displayed in the tachometer/display.

•

Orange lamp flashing in alarm panel.

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 circuit in signal cable.

•

Open circuit in the sensor negative cable.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in sockets 18 and 27 in engine connector B. 3 Check the sensor.

D9, D12, D16

D11, D13

p0004941

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b

Circuit description a

GR / W

P0007217

a

Coolant temperature sensor

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 Checking signal cable, coolant temperature sensor Checking the coolant temperature sensor

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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 •

Warning is displayed in the tachometer/display.

•

Coolant indicator lamp flashing in alarm panel.

Symptom:

None

Conditions for fault code:

Coolant level too low

Possible reason:

Suitable action:

•

Low coolant level.

•

Coolant leakage

•

Short circuit between pin B23 and battery negative.

•

Faulty coolant level switch

1 Check the coolant level.

2 Check that no leakage occurs.

3 Check the wiring to the coolant level switch.

4 Check the level switch.

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 harness between the coolant level switch and the EMS 2.

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b

Circuit description a

P0007222

a

Coolant level monitor

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 Checking negative cable, coolant switch Checking the coolant switch

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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 •

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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:

•

Fault in sensor cables.

•

Worn or damaged cylinder liners, pistons or piston rings

•

Blocked crankcase ventilation

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check and clean the crankcase ventilation system.

3 Check the sensor by checking the fuel crankcase pressure.

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

Faulty sensor/Fault in sensor circuit •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between the sensor signal cable and the sensor 5 V supply cable or battery voltage.

•

Open circuit in the sensor negative cable.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in socket 18 in engine connector B. 3 Check the sensor.

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

Faulty sensor/Fault in sensor circuit •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 circuit in 5 V supply cable.

•

Open circuit in signal cable.

•

Short circuit between the sensor signal cable and the sensor negative cable.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in sockets 17 and 28 in engine connector B. 3 Check sensor.

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b

Circuit description a

GN / R

P0007226

a

Crankcase pressure sensor

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 Checking negative cable, crankcase pressure sensor Checking signal cable, crankcase pressure sensor Checking the crankcase pressure sensor

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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 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.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

•

Battery indicator lamp flashing in alarm panel.

Symptom:

None

Preconditions:

Data valid but below operational range.

Conditions for fault code:

Possible reason:

Suitable action:

•

Battery voltage lower than 13.2 V while engine running.

(Applies to 12 V system).

•

Battery voltage lower than 25.5 V while engine running.

(Applies to 24 V system).

•

Alternator drive belt, alternator not charging.

•

Fault in battery, cables or connectors.

•

Faulty alternator

•

Faulty sensor cable

1 Check that the alternator charges.

2 Check the sensor cable.

3 Check the battery cables and the battery connections.

4 Check/charge the batteries.

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:

An orange lamp flashes in the alarm panel.

Symptom:

None

Conditions for fault code:

Timeout in communication on the secondary bus J1587.

Possible reason: Suitable action:

•

Break in communication from the PCU.

•

Faulty PCU

1 Check the communication cables between the engine and the PCU. 2 Check that the PCU is programmed for the correct engine 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 •

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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 exhaust pipe has not been damaged and that there are no restrictions.

2 Check the sensor.

3 Check the exhaust back pressure.

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

Faulty sensor/Fault in sensor circuit •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between the sensor signal cable and the sensor negative cable.

•

Faulty sensor.

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

2 Check the sensor.

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

Faulty sensor/Fault in sensor circuit

Fault indication:

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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:

Suitable action:

•

Open circuit in sensor signal cable.

•

Open circuit in sensor negative cable.

•

Faulty sensor.

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

2 Check contact pressure in sockets 18 and 44 in engine connector B. 3 Check the sensor.

D9 CC, D16 Conn. B

(+) 44

VO

1 1

SB

1 2 2 2

(-) 18

Circuit description

EMS2

(+) 44

SB BN

2 1

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 1

(-) 18

2 2

D11 Conn. B

The exhaust temperature sensor is a Pt 200 sensor whose resistance changes depending on exhaust temperature. Resistance increases as exhaust temperature rises.

EMS2

(+) 44

SB GR

1 2 2 2

(-) 18

1 1

D13 Conn. B

EMS2 P0007230

Measurements Checking signal cable, exhaust temperature sensor Checking negative cable, exhaust temperature sensor Checking exhaust temperature sensor

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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 •

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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 the oil level in the engine.

2 Check the coolant level and the engine temperature.

3 Check that no leakage occurs.

4 Check the sensor.

5 Clean the oil cooler system and check the bypass valve for the oil cooler.

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 •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between the sensor signal cable and the sensor negative cable.

•

Faulty sensor

1 Check cables and connectors between the sensor and engine control unit.

2 Check sensor.

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

Faulty sensor/Fault in sensor circuit •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between the sensor signal cable and the sensor 5 V supply cable or battery voltage.

•

Open circuit in signal cable.

•

Open circuit in sensor negative cable

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in socket 11, engine connector A, and socket 11 in engine connector B. 3 Check the sensor.

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a (+)7 (-)11 31

R SB GR / OR

EMS2 b 11

BL / OR

P0007206

a

ConnectorA Color: Black

b

Connector B Color: GrAy

c

Oil temperature sensor

c 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 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 negative via engine control unit connector pin 11.

Refer to the "resistance/temperature, engine" table.

Measurements Checking negative cable, oil temperature sensor Checking power supply cable, oil temperature sensor Checking oil temperature sensor

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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 •

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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 the oil level in the engine.

2 Check the coolant level and the engine temperature.

3 Check that no leakage occurs.

4 Check the sensor.

5 Clean the oil cooler system and check the bypass valve for the oil cooler.

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 •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between the oil temperature signal cable to the sensor negative cable.

•

Short circuit between oil temperature signal cable and the sensor 5 V supply cable.

•

Short circuit between oil temperature signal cable and oil level signal cable.

•

Faulty sensor

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

2 Check the sensor.

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

Faulty sensor/Fault in sensor circuit •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 circuit in the oil temperature signal cable.

•

Open circuit in the sensor negative cable.

•

Faulty sensor.

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

2 Check contact pressure in socket 10, engine connector B, and socket 31 in engine connector A. 3 Check the sensor.

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Circuit description D13

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.

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

Oil temperature and level

Measurements Checking negative cable, oil temperature sensor Checking signal cable, oil temperature sensor Checking oil temperature sensor

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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.

•

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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:

98

1 After the engine has stopped, search for the reason for the high 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.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

Symptom:

The starter motor is not activated.

Preconditions:

General checks for starter motor problems: •

Check the starter motor cables and connections.

•

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

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 pre-start and start relay pull during a start attempt.

2 Check the cables between the engine control unit and the start relay.

3 Check contact pressure in socket B29 in engine connector.

4 Check that socket B29 in the engine connector is not 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 relay wiring.

Measurements Checking the starter motor solenoid Checking the pre-start relay

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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:

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

Symptom:

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 between EMS2 pin A27 to the external stop relay connector.

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

Stop input is activated.

•

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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:

•

The stop relay is activated.

•

Faulty stop relay

•

Faulty relay cables

•

Short circuit between the signal cable to battery positive.

1 Check what triggered activation of the stop relay, fire alarm.

2 Check the connector that activates the stop relay.

3 Check the stop relay.

4 Check cables and connectors between the control unit 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

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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.

•

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

Symptom:

Engine is derated.

Conditions for fault code:

Piston cooling pressure is too low.

Suitable action:

1 Check the sensor by checking the piston cooling oil pressure with a manometer. Be sure not to load the engine while doing this.

Please refer to Engine Protection Map 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 •

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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 between the sensor signal cable and the sensor 5 V supply cable or battery voltage.

•

Open circuit in the sensor negative cable.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in socket 11 in engine connector B. 3 Check the sensor.

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

Defective sensor/Defect in sensor circuit •

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

Symptom:

Engine is derated.

Conditions for fault code:

Engine control unit pin A23 voltage lower than 0.30 volts.

Possible reason:

Suitable action:

•

Open circuit in 5 V supply cable.

•

Open circuit in signal cable.

•

Short circuit between the sensor signal cable and the sensor negative cable.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in sockets 7 and 23 in engine connector B. 3 Check the sensor.

Circuit description 23

GR/R

(+)7

R

(-)11

SB

EMS2 P0008475

a

Piston cooling pressure

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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)* 4.5 VDC at 700 kPa (101.5 PSI)* P0007192

kPa

NOTICE! * At normal atmospheric pressure.

V: Output voltage kPa: Piston cooling pressure

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

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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.

•

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

Symptom:

Engine power is reduced.

Preconditions:

Piston cooling pressure is too low.

Suitable action:

1 Check the sensor by checking the piston cooling oil pressure with a manometer. Be sure not to load the engine while doing this.

Please refer to Engine Protection Map to see what rpm a piston cooling pressure should be expected.

SB

a 2

10 SB

P1

14 GR / R

EMS P0007245

a

Piston cooling pressure switch

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 limit of 150 kPa determines when the monitor switches potential.

Monitor potential is low when piston cooling pressure exceeds this value.

At idle the monitor may have high potential without any fault code being triggered.

Measurements Checking negative cable, piston cooling pressure sensor Checking power supply cable, piston cooling pressure sensor

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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 •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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

•

Fault in the communication between the EMS and the PCU.

•

Open circuit in the power supply cable between the engine control unit and the PCU.

•

Faulty PCU

1 If an HCU fault code exists regarding the throttle lever: Check that there is a signal between the throttle linkage and the HCU. 2 Check all connectors and wires between the EMS and the PCU. 3 Check that the PCU is 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 engine protection criteria that set this 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 •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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

•

Fault in the communication between the EMS and the PCU.

•

Open circuit in the power supply cable between the engine control unit and the PCU.

•

Faulty PCU

1 If an HCU fault code exists regarding the throttle lever: Check that there is a signal between the throttle linkage and the HCU. 2 Check all connectors and wires between the EMS and the PCU. 3 Check that the PCU is 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 •

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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 that the seawater intake is not blocked.

2 Check that the seawater filter is not blocked..

3 Check that no leakage occurs.

4 Check the impeller in the seawater pump..

5 Check the sensor by checking the seawater pressure.

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

Defective sensor/Defect in sensor circuit.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 circuit in the sensor negative cable.

•

Short circuit between the sensor signal cable and the sensor 5 V supply cable or battery voltage.

•

Faulty sensor.

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

2 Check contact pressure in socket 11 in engine connector A. 3 Check the sensor.

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

Defective sensor/Defect in sensor circuit.

Fault indication:

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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:

Suitable action:

•

Open circuit in the sensor 5 V supply cable.

•

Open circuit in sensor signal cable.

•

Short circuit between the sensor signal cable and the sensor negative cable.

•

Faulty sensor.

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

2 Check contact pressure in sockets 7 and 19 in engine connector A. 3 Check the sensor.

a

Circuit description (-) 11

SB

b 1 4

(+ ) 7

R 19

GR P0007246

a

Connector A

b

Seawater pressure sensor

P2

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 Voltage Supply

0–300 kPa (0–3 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 300 kPa (3 bar)

Measurements Checking negative cable, seawater pressure sensor Checking supply cable, seawater pressure sensor Checking signal cable, seawater pressure sensor Checking the seawater pressure sensor

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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

Unit injector 3

SID 4

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.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

•

Engine performance is reduced.

•

The engine can run on three or five cylinders.

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

•

Injector activated

•

Short circuit to battery voltage on the pin on every injector low voltage side.* NOTICE! * Engine control unit: Pins 16, 24, 32, 48, 56.

Possible reason: Suitable action:

•

Short circuit between high voltage and low voltage sides.

•

Short circuit to battery voltage, low voltage side, injection cable.

1 Check the cables between the injector and the engine control 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.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

•

Engine performance is reduced.

•

The engine can run on three or five cylinders.

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

•

Injector activated

•

Short circuit to battery voltage on the pin on every injector low voltage* or high voltage side**.

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:

Short circuit between the cables on every injector low voltage or high voltage side and battery negative.

Suitable action:

1 Check the cables between the injector and the engine control 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.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

•

Engine performance is reduced.

•

The engine can run on three or five cylinders.

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

•

Injector activated

•

Open circuit in the injector circuit.

•

Open circuit in the cables on the low voltage or high voltage side.

•

If three fault codes are triggered (a bank), the open circuit is on that bank's high voltage side.

•

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

1 Check the cables between the injector and the engine control unit.

2 Check the contact pressure in all sockets to unit injectors in engine connector A.

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

Fault in injection system.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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:

•

Injector activated

•

Too high cylinder balancing data

•

Poor compression.

•

Fault in injector.

•

Asymmetric engine 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 compression test and a cylinder balance test, using VODIA, to localize the fault source.

2 Check the injector by changing it. The injectors are manufactured with 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. 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.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 between the injector and the engine control unit.

2 Check the contact pressure in all sockets to unit injectors in engine connector A. 3 Check the cable connection to the injector.

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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

Unit injector, cylinders 1-6

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

b

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

1 2 3

4 5

D11, D13 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

Unit injector, cylinders 1-6

Measurements Injector trim Checking the injector coils

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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:

•

Monitoring cam speed sensor voltage waveform (clean Vout signal without peaks and variations) and set fault when not according to specification

•

Faulty synchronization between camshaft and crankshaft

•

Incorrectly mounted sensor (incorrect distance between sensor and toothed wheel, or loose sensor).

•

Intermittent contact or electrical interference on camshaft position signal.

•

Faulty correlation between crank and cam signals, bad timing.

•

Polarity fault, the cables to the sensor are shifted.

•

Faulty sensor.

•

Damaged toothed wheel

1 Check the signal. Use an oscilloscope.

2 Check cables and connectors between the sensor and engine control unit.

3 Check that the sensor is correctly installed and that the distance between the toothed wheel and the sensor is correct. Refer to workshop manual (group 21–26).

4 Check contact pressure in sockets 45 and 46 in engine connector A. 5 Check the engine timing. Refer to workshop manual (group 21–26).

6 Check the sensor.

7 Check that the toothed wheel is not damaged.

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 circuit or short circuited sensor cables.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in sockets 45 and 46 in engine connector A. 3 Check the sensor.

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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 fault when not according to specification.

Possible reason:

Suitable action:

•

Incorrectly mounted sensor (incorrect distance between sensor and toothed wheel, or loose sensor).

•

Intermittent contact or electrical interference on camshaft position signal.

•

Faulty sensor

1 Check the signal. Use an oscilloscope.

2 Check cables and connectors between the sensor and engine control unit.

3 Check that the sensor is correctly installed and that the distance between the toothed wheel and the sensor is correct. Refer to the workshop manual.

4 Check contact pressure in sockets 45 and 46 in engine connector A. 5 Check the sensor.

D9, D12, D16

D11, D13

P0008694

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30-2 Fault Tracing

D11, D13, D16 Conn. A

Circuit description b

D9, D12 Conn. A

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 the camshaft and reluctor wheel rotates, impulses are generated in the sensor. The 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

Tachometer sensor (camshaft)

47700583 08-2019 © AB VOLVO PENTA

Checking camshaft sensor

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30-2 Fault Tracing

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:

Yellow alarm status

Fault stored in memory:

Yes

Symptom:

Conditions for fault code: Possible reason:

Suitable action:

•

The engine start time will increase.

•

Engine is running with imprecise timing causing risk of high fuel consumption and smoke.

•

Cylinder balancing not working with risk of uneven running.

Monitoring crank speed sensor voltage waveform (clean Vout signal without peaks and variations) and set fault when not according to specification.

•

Incorrectly mounted sensor (incorrect distance between sensor and flywheel, or loose sensor).

•

Intermittent contact or electrical interference on crankshaft position signal.

•

Polarity fault, the cables to the sensor are shifted.

•

Faulty sensor.

•

Damaged flywheel

1 Check the signal. Use an oscilloscope.

2 Check cables and connectors between the sensor and engine control unit.

3 Check that the sensor is correctly installed and that the distance between the flywheel and the sensor is correct. Refer to the workshop manual.

4 Check contact pressure in sockets 37 and 38 in engine connector A. 5 Check the sensor.

6 Check that the flywheel is not damaged.

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30-2 Fault Tracing

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:

•

The engine start time will increase.

•

Engine is running with imprecise timing causing risk of high fuel consumption and smoke.

•

Cylinder balancing not working with risk of uneven running.

No crank signal.

•

Open circuit or short circuited sensor cables.

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit.

2 Check contact pressure in sockets 37 and 38 in engine connector A. 3 Check the sensor.

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30-2 Fault Tracing

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:

•

The engine start time will increase.

•

Engine is running with imprecise timing causing risk of high fuel consumption and smoke.

•

Cylinder balancing not working with risk of uneven running.

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 mounted sensor (incorrect distance between sensor and flywheel, or loose sensor).

•

Intermittent contact or electrical interference on crankshaft position signal.

•

Faulty sensor

1 Check the signal. Use an oscilloscope.

2 Check cables and connectors between the sensor and engine control unit.

3 Check that the sensor is correctly installed and that the distance between the toothed wheel and the sensor is correct. Refer to the workshop manual.

4 Check contact pressure in sockets 37 and 38 in engine connector A. 5 Check the sensor.

D9, D12, D16

D11, D13

P0008694

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30-2 Fault Tracing

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). 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

Tachometer sensor (flywheel)

Measurements Checking flywheel sensor

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30-2 Fault Tracing

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.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 circuited control valve signal to battery positive.

•

Fault in the wastegate valve.

1 Check cables and connectors between the control unit and the control valve.

2 Check the wastegate valve.

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

Fault in wastegate valve or fault in circuit.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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 circuited control valve signal to battery negative.

•

Fault in the wastegate valve.

1 Check cables and connectors between the control unit and the control valve.

2 Check the wastegate valve.

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30-2 Fault Tracing

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

Fault in wastegate valve or fault in circuit.

Fault indication:

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

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: Suitable action:

•

Open circuit in control valve signal.

•

Fault in the wastegate valve.

1 Check cables and connectors between the control unit and the control valve.

2 Check contact pressure in socket 38 in engine connector B. 3 Check the wastegate valve.

Circuit description D12, D13 single turbo (not classified) b a

(+) 57 R / BL (+) 60 R / BL

2 1

D12: GN 38 D13: GN / OR 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

Wastegate Valve

b

Connector B

D13CC single turbo a 58 BL/R EMS2 b 38 GN/OR

D12, D13 single turbo The engine is equipped with a turbocharger with waste gate valve. The valve is located beneath the 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.

+15 PM

2

c

1

The control valve is controlled by current from the engine control unit with the aid of a PWM signal. The greater the current supplied to the control valve, the greater the inlet pressure increase. Inlet pressure is constantly monitored by a sensor installed in the inlet manifold.

P0017178

P0017178

a

Connector A

b

Connector B

c

Wastegate Valve

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30-2 Fault Tracing 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

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30-2 Fault Tracing

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 circuited solenoid supply cable to battery voltage.

•

Short circuit in solenoid negative cable or supply cable.

•

Faulty clutch

1 Check cables and connectors between the control unit and the supercharger.

2 Magnetic clutch

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 solenoid power supply cable to battery negative.

•

Faulty clutch

1 Check cables and connectors between the control unit and the supercharger.

2 Magnetic clutch

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 circuit in control valve signal.

•

Faulty wastegate valve

1 Check cables and connectors between the control unit and the control valve.

2 Check the contact pressure in socket 38 in the engine connector B. 3 Check the wastegate valve.

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30-2 Fault Tracing

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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30-2 Fault Tracing

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.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm panel or some display 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 supply voltage to the sensors which have set the fault codes.

2 Check the sensor cables.

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

Fault in sensor supply circuit.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm panel or some display values show - - -.

Symptom:

None

Conditions for fault code:

Voltage below normal or shorted to lower voltage

Possible reason:

Suitable action:

•

Coolant temperature sensor, sensor signal cable short circuit to 5 V power.

•

Oil pressure sensor, sensor signal cable short circuit to 5 V power.

•

Charge air pressure sensor, sensor signal cable short circuit to 5 V power.

•

Fuel pressure sensor, sensor signal cable short circuit to 5 V power.

•

Coolant pressure sensor, sensor signal cable short circuit to 5 V power.

•

Crankcase pressure sensor, sensor signal cable short circuit to 5 V power.

•

Seawater pressure sensor, sensor signal cable short circuit to 5 V power.

•

Short circuited power cable to battery negative.

•

Short circuited signal cable to battery negative.

1 Check the supply voltage to the above-mentioned sensors.

2 Check the sensor cables.

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30-2 Fault Tracing

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 •

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

Symptom:

None

Conditions for fault code:

Software checksum error

Possible reason:

Failed download

Suitable action:

1 Try to reload the software.

2 Try another EECU.

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30-2 Fault Tracing

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:

Defective component.

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

Symptom:

None

Conditions for fault code:

Internal fault in engine control unit

Suitable action:

1 Change the engine ECU.

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30-2 Fault Tracing

MID 128, SID 231 SAE J1939 data link MID 128: Engine control unit FMI 2 – Data erratic, intermittent or incorrect Fault code explanation:

Communication fault J1939

Fault indication:

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

Symptom:

None

Conditions for fault code:

Data bus, CAN, communication not found.

Possible reason:

Suitable action:

•

CAN H short circuited to battery negative on pin 3.

•

Conductors in control link CAN H and CAN L short circuited to each other.

•

CAN L short circuited to supply voltage on pin 4.

1 Check the data bus cables and terminals between the engine control unit and PCU. Refer to ”Functional disruptions, checking bus cables”.

FMI 9 – Abnormal update rate Fault code explanation:

Communication fault J1939

Fault indication:

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

Symptom:

None

Conditions for fault code:

Abnormal update rate

Suitable action:

1 Check the data bus cables and terminals between the engine control unit and PCU. Refer to ”Functional disruptions, checking bus cables”.

Circuit description A B C D E F G H

a

P0007123

a

PCU connector X3 Color: Pink

b

Engine connector “BUS INTERFACE”

130

b

A B C D H F G E

A CAN H – Data link to engine B CAN L – Data link to engine C Input voltage, 0 V D Input voltage, 24 V E J1708B – Data link to engine F Not used G J1708A – Data link to engine H Ignition signal

47700583 08-2019 © AB VOLVO PENTA

30-2 Fault Tracing

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:

Yellow alarm status

Fault stored in memory:

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 Engine Protection Map.

Possible reason:

Suitable action:

•

Crushed/leaking/blocked hose on the suction side (seawater)

•

Worn impeller in seawater pump

•

Poor flow through the sea water system

•

Faulty sensor

1 Check the sea water system for leakage and for squeezed hoses.

2 Check the impeller in the sea water pump.

3 Check the flow in the sea water system.

4 Check the exhaust manifold water temperature 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 circuited sensor 5 V supply cable to battery voltage.

•

Short circuited sensor signal cable to battery voltage or 5 V voltage.

•

Faulty sensor

1 Check all cables and connectors between the sensor and the engine ECU. 2 Check the sensor.

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30-2 Fault Tracing

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 circuited sensor signal cable to battery negative.

•

Faulty sensor

1 Check all cables and connectors between the sensor and the engine ECU. 2 Check the sensor.

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 circuit in sensor signal cable.

•

Open circuit in sensor battery negative cable.

•

Faulty sensor

1 Check all cables and connectors between the sensor and the engine ECU. 2 Check the sensor.

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

132

Engine ECU B18 B43

Signal type batTemp input

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30-2 Fault Tracing

MID 128, PSID 216 Data Link, MID187 MID 128: Engine control unit FMI 9 – Abnormal update rate Fault code explanation:

Communication fault J1939

Fault indication:

•

Warning is displayed in the tachometer/display.

•

An orange lamp flashes in the alarm display.

Symptom:

None

Conditions for fault code:

Abnormal updating rate on the J1939 data bus between the EMS and the PCU

Possible reason:

Suitable action:

•

AUX stop button is activated.

•

Open circuit in CAN L or CAN H.

•

One or two conductors in CAN short circuited to battery negative, pin 3.

•

Conductors in control link CAN H and CAN L short circuited to each other.

•

CAN H short circuited to the power supply, pin 4.

•

CAN short circuited to ”ignition signal”.

•

Intermittent contact in power supply to data bus

•

Open circuit in the power supply cable between the engine control unit and the PCU.

1 Check that the AUX stop button is not activated.

2 Check the databus cables and the connections between the engine control unit and the PCU. Refer to ”Functional disruptions, checking bus cables”.

3 Check the power supply cable between the engine control unit and the PCU. 4 Check contact pressure in sockets 51 and 55 in engine connector B.

Circuit description A B C D E F G H

a

b

P0007123

a

PCU connector X3 Color: Pink

b

Engine connector “BUS INTERFACE”

47700583 08-2019 © AB VOLVO PENTA

A B C D H F G E

A CAN H – Data link to engine B CAN L – Data link to engine C Input voltage, 0 V D Input voltage, 24 V E J1708B – Data link to engine F Not used G J1708A – Data link to engine H Ignition signal

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30-2 Fault Tracing

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: Fault indication:

Poor batteries or charging 1 A warning is shown in the tachometer/display.

2 At low charging: Battery indicator lamp flashing in alarm panel.

3 A red lamp flashes in the alarm display + audible warning.

Symptom:

None

Conditions for fault code:

Preconditions:

•

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 General checking 1 Check the battery electrolyte level.

2 Check the density in all of the batteries' cells.

Possible reason: Suitable action:

•

Battery voltage too low

•

Poor charging

1 Check that the cable harness between the battery and the power module is undamaged.

2 Check the batteries condition.

3 Check that the alternator charges.

e

Circuit description

PM 1 15 29 67 8 14 28 42

R R

d SB

c

a

c

SB

b

P0017212

a

Primary Battery

b

Secondary Battery

c

Main battery switch

d

Starter motor / junction 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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30-2 Fault Tracing

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: Fault indication:

Poor batteries or charging 1 Warning is displayed in the tachometer/display.

2 At low charging: Battery indicator lamp flashing in alarm panel.

3 A red lamp flashes in the alarm display + audible warning.

Symptom:

None

Conditions for fault code:

Preconditions:

•

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 General checking 1 Check the battery electrolyte level.

2 Check the density in all of the batteries' cells.

Possible reason: Suitable action:

•

Battery voltage too low

•

Poor charging

1 Check that the cable harness between the battery and the power module is undamaged.

2 Check the batteries condition.

3 Check that the alternator charges.

e

Circuit description

PM 1 15 29 67 8 14 28 42

R R

d SB

c

a

c

SB

b

P0017212

a

Primary Battery

b

Secondary Battery

c

Main battery switch

d

Starter motor / junction 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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30-2 Fault Tracing

MID 158, PSID 4, 30 supply fuse MID 158: Power module FMI 6 – Current above normal or short circuit to battery negative Fault code explanation:

Too high current output

Fault indication:

•

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

Symptom:

None

Conditions for fault code:

Excessive power supply. (Power supply to other systems, pin 4 in the 8-pole engine connector).

Possible reason: Suitable action:

•

Short circuit in the system.

•

Too high load

1 Check for short circuits in the cable harness from the supply module to the 8-pole engine connector.

2 Reduce load.

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-pole connector

136

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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30-2 Fault Tracing

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.

•

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

•

Warning is removed only after new startup sequence.

•

Receiving warnings but fully functional (if one wire is broken).

Redundant wiring.

•

No power to EMS, not able to start engine (if two wires are broken).

Open circuit in at least one of the supply voltage wires to the EMS2.

•

Emergency stop button may be activated during power up (button locked in depressed position).

•

Open circuit in one of the cables to the emergency stop button.

•

Open circuit in one or two wires from emergency stop button to EMS.

1 Reset the emergency stop button (pull the button up until a click is heard). Reset system with main switches for primary and secondary batteries.

2 Check that the EMS2 has supply voltage on both pin B57 and B60.

3 Check the emergency stop button internal switches / wiring.

4 This fault code might be wrongly set if power module is of older 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 •

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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:

•

Short circuit in the system.

•

Too high load

1 Check the cable harness from the power module for short circuit.

2 Reduce load.

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30-2 Fault Tracing

(D13) BL/R 5

2 c

1 2

3 4 b

57 60 EMS2 (B) P0017218

a

Power Module

b

Emergency Stop

c

Shutdown relay (only D13)

138

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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30-2 Fault Tracing

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 •

Warning is displayed in the tachometer/display.

•

A red lamp flashes in the alarm display + audible warning.

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: Suitable action:

•

Short circuit on pin 4 and pin 5 on power module.

•

Too high load Continuously more than 7A.

1 Check the cable harness from the power module for short circuit.

2 Reduce load.

Circuit description BL/R

4

1

b

2 c

1

5

PM

a

GN

A27

EMS2

P0017253

a

Power Module

b

Easy Link connector

c

External stop

47700583 08-2019 © AB VOLVO PENTA

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.

139

30-2 Fault Tracing

Measurements Checking supply cable, coolant pressure sensor Tools: 88890074 Multimeter 9998534 Break-out cable 885675 Break-out cable 1 NOTICE! Turn off ignition.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Use multimeter 88890074 for voltage measurement.

4 Turn on ignition.

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! Cut the current with the main switch.

2 Disconnect the connector from the sensor 3 Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

4 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

4

9998534 P0007186

140

Measurement points

Nominal value

4 - Battery negative

R≈0Ω

NOTICE! Battery negative (–) on alternator or starter motor.

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30-2 Fault Tracing

Checking signal cable, coolant pressure sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Disconnect the connector from the sensor 3 Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

4 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

Measurement points

Nominal value

2-4

R ≈ 80 - 120 kΩ

NOTICE! Measurement is done to eliminate short 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 Turn off ignition.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor 3 Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

4 Use multimeter 88890074 for voltage measurement.

5 Turn on ignition.

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 0 kPa (0 bar) 4,5 VDC at 300 kPa (3 bar)

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141

30-2 Fault Tracing

Checking supply cable, fuel pressure sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Turn the starter key to position 1.

4 Use multimeter 88890074 for voltage 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 current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

4

9998534 P0007190

142

Measurement points

Nominal value

4 - Battery negative*

R≈0Ω

NOTICE! Battery negative (–) on alternator or starter motor.

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30-2 Fault Tracing

Checking signal cable, fuel pressure sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

Measurement points

Nominal value

2 - Battery negative*

R ≈ 80 - 120 kΩ

NOTICE! Measurement is done to eliminate short circuiting or breaks in the cable to the engine control unit.

NOTICE! Battery negative (–) on alternator or starter 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 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Turn the starter key to position 1.

4 Use multimeter 88890074 for voltage measurement.

47700583 08-2019 © AB VOLVO PENTA

Measurement points

Nominal value

2-4

U ≈ 0,5 V

143

30-2 Fault Tracing

Checking the wastegate valve Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Remove the connector from the wastegate valve.

Connect break-out cable 9998534 or 885675 to the valve. Do not connect the other end of the adapter cable.

3 Use multimeter 88890074 to do resistance measurements.

NOTICE! Measurement is done to eliminate short circuiting or breaks in the wastegate valve.

Measurement points

Nominal value

1–2

R = 90 ± 4.5 Ω at 20 °C (68 °F)

885 675 P0008932

144

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30-2 Fault Tracing

Checking flywheel sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Remove the connector from the sensor and remove the sensor from the flywheel housing.

Check that the sensor has no external damage or swarf adhering to it.

1

3 Connect break-out cable 9998534 or 885675 to the sensor. Do not connect the other end of the adapter cable.

4 Use multimeter 88890074 to do resistance measurements.

2 P0007251

Measurement points

Nominal value

1–2

R ≈ 0.9 kΩ*

NOTICE! * ±10% at 20 °C (68 °F).

5 Use multimeter 9812519 for voltage measurement.

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 Install the sensor.

Checking supply cable, water switch, fuel filter Tools: 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the water in fuel switch.

3 Use multimeter 88890074 for voltage measurement.

4 NOTICE! Turn the starter key to position 1.

47700583 08-2019 © AB VOLVO PENTA

Measurement points

Nominal value

Red/Blue conductor Black conductor

U ≈ Battery voltage

145

30-2 Fault Tracing

Checking negative cable, water switch, fuel filter Tools: 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Disconnect the connector from the water in fuel switch.

3 Use multimeter 88890074 to do resistance 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 the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the water in fuel switch.

3 Use multimeter 88890074 for voltage measurement.

4 NOTICE! Turn the starter key to position 1.

146

Measurement points

Nominal value

Yellow conductor - Black conductor

U ≈ Battery voltage x 0,8

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30-2 Fault Tracing

Checking the water in fuel switch, fuel filter 2 1

D9, D12, D16

+24V

3

+24V

H2O P0007196

1

Red conductor in connector.

2

Yellow conductor in connector.

3

Black conductor in connector.

1 Remove the connector. Remove the water switch from the fuel fine filters.

Make sure that a collection vessel is available as some fuel may run out of the filter.

2 Connect the red wire (2) to a +24 V power source.

Use multimeter 88890074 for voltage measurement.

Connect the multimeter between the yellow wire (1) in the connector and the red wire (2).

Connect the connector's black wire (3) to ground (-).

The multimeter should display 0 V. 3 Dip the monitor contact pins into a dish of water.

The multimeter must show 23-24 V when there is water between the contact pins.

4 The multimeter should display 0 V when the switch is lifted out of the water.

D11 1 Remove the switch.

2 Disconnect the connector from the water in fuel switch.

3 Use multimeter 88890074 to do resistance measurements.

47700583 08-2019 © AB VOLVO PENTA

Measurement points

Nominal value

Monitor dipped in water.

R≈0Ω

Monitor dipped in fuel.

R≈∞Ω

147

30-2 Fault Tracing

Checking camshaft sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Undo the connector from the sensor and remove the sensor from the cylinder head.

Check that the sensor has no external damage or swarf adhering to it.

3 Connect adapter cable 9998534 or 885675 to the sensor. Do not connect the other end of the cable.

4 Use multimeter 9812519 to measure resistances.

Nominal value

1–2

R ≈ 0.9 kΩ*

NOTICE! * ±10% at 20 °C (68 °F).

5

75

V

1

2

3

4

8856

Measurement points

885 675

1

2

5 Use multimeter 88890074 for voltage 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.

6 Install the sensor.

1

2

3

4

5

75

8856

885 675

1

2

P0008931

148

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30-2 Fault Tracing

Checking supply cable, oil level switch Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Use multimeter 88890074 for voltage measurement.

4 NOTICE! 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! Cut the current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

Measurement points

Nominal value

2 - Battery negative

R≈0Ω

NOTICE! Battery negative (–) on alternator or starter motor.

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149

30-2 Fault Tracing

Checking the oil level switch D11, D9 Tools: 9998534 Break-out cable 885675 Break-out cable 1 Put a suitable vessel underneath the oil pan.

2 Release the connector and remove the monitor from the engine.

NOTICE! Temporarily install a bottom plug (M18 x 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 Connect break-out cable 9998534 or 885675 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 switch vertically into a vessel containing engine oil. The bulb should light up.

5 Lift the sensor up out of the oil bath and check that the bulb goes out.

150

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30-2 Fault Tracing

Checking the oil level sensor D12, D13, D16 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Connect break-out cable 9998534 or 885675 to the sensor. Do not connect the other end of the adapter cable.

3 Use multimeter 88890074 for resistance measurement.

Measurement points

Nominal value

1-2

R ≈ 10–14 Ω

NOTICE! Even if the nominal value is correct the sensor could be faulty.

P0007205

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151

30-2 Fault Tracing

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 actuators in each injector, and deviations in fuel delivery due to variations between the different nozzle flows are also corrected.

NOTICE! Write down the new injector codes before 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 Connect the VODIA tool.

2 Go into the “Service and maintenance” menu in VODIA. 3 Select “Parameter, programming”.

4 Click “Run”.

5 Select the cylinder number corresponding to the injector that has been changed.

6 Enter the new injector code. Click “OK”.

7 Close “Parameter, programming”.

8 VODIA will instruct you to “Turn off the main switch”; follow subsequent instructions.

9 Report parameters according to items 10-13 in "Program the control unit".

152

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30-2 Fault Tracing

Checking the injector coils Tools: 9998699 Break-out box 9990014 Break-out cable 88890074 Multimeter 1 Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Cut the current with the main switch.

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 Connect 9998699 Break-out box and 9990014 Break-out cable as described in section Connection of 9998699 Break-out box to EMS 2 in chapter Repair Instructions.

4 Use multimeter 88890074 to do resistance 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 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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153

30-2 Fault Tracing

D11

154

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

R ≈ 1.4-3 Ω

16 – 59

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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30-2 Fault Tracing

Checking negative cable, intake manifold temperature sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance 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 motor.

Checking signal cable, intake manifold temperature sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Turn the starter key to position 1.

4 Use multimeter 88890074 for voltage measurement.

Measurement points

Nominal value

D9, D12

3-4

U≈5V

D11, D16

1-2

U≈5V

5 Turn off ignition.

6 Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

7 Turn on ignition.

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.

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155

30-2 Fault Tracing

Checking the intake manifold temperature sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

NOTICE! Do not connect the other end of the adapter cable to the engine cable harness, as this may cause incorrect measurements.

3 Use multimeter 88890074 to measure 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))

156

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30-2 Fault Tracing

Checking supply cable, oil pressure sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Use multimeter 88890074 for voltage measurement.

4 NOTICE! 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! Cut the current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

Measurement points

Nominal value

2 - Battery negative*

R ≈ 80 - 120 kΩ

NOTICE! * The measurement should exclude short circuiting or open circuit in the cable to the engine control unit.

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157

30-2 Fault Tracing

Checking the oil pressure sensor NOTICE! Combined sensor, oil pressure and oil temperature (engine).

Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Use multimeter 88890074 for voltage measurement.

4 NOTICE! Turn the starter key to position 1.

Measurement points

Nominal value

2-4

U ≈ 0,5 V*

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.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

Measurement points

Nominal value

4 - Battery negative terminal

R≈0Ω

4

9998534 P0007190

158

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30-2 Fault Tracing

Checking supply cable, seawater pressure sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn off ignition.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Use multimeter 88890074 for voltage measurement.

4 NOTICE! 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.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

Measurement points

Nominal value

2 - Battery negative terminal

R ≈ 80 - 120 kΩ

NOTICE! Measurement is done to eliminate short circuiting or breaks in the cable to the engine control unit.

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159

30-2 Fault Tracing

Checking the seawater pressure sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn off ignition.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Use multimeter 88890074 for voltage measurement.

4 Turn on ignition.

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 current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

160

Measurement points

Nominal value

2 - Battery negative terminal

R≈0Ω

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30-2 Fault Tracing

Checking power supply cable, piston cooling pressure sensor D12, D16 Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 for voltage measurement.

4 Turn the starter key to position 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 with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

4

9998534

Measurement points

Nominal value

4 - Battery negative terminal

R≈0Ω

P0007186

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161

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 the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 for voltage measurement.

4

4 Turn the starter key to position 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 Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Turn the starter key to position 1.

4 Use multimeter 88890074 for voltage measurement.

162

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! Cut the current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance 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 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.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance 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 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/ charge air temperature Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Turn the starter key to position 1.

4 Use multimeter 88890074 to do voltage measurement towards the engine control unit.

Measurement points

Nominal value

D9, D12

2-4

U ≈ 1,2 V*

D11, D16

1-4

U ≈ 1,1 V*

NOTICE! * At normal atmospheric pressure

Checking supply cable, air inlet 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 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Turn the starter key to position 1.

4 Use multimeter 88890074 for voltage measurement.

164

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.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

Measurement points

Nominal value

1 - Battery negative*

R≈0Ω

NOTICE! * Battery negative (–) on alternator or starter motor.

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30-2 Fault Tracing

Checking signal cable, coolant temperature sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do voltage measurement towards the engine control unit.

4 Turn the starter key to position 1.

Measurement points

Nominal value

1-2

U≈5V

5 Turn off ignition.

6 Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

7 Turn on ignition.

Measurement points

Nominal value

1-2

U ≈ 0,5 - 4,5V*

NOTICE! * Depending on temperature.

166

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30-2 Fault Tracing

Checking the coolant temperature sensor Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the sensor.

Do not connect the other end of the adapter cable.

3 Use multimeter 88890074 to measure 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 off ignition (If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 for voltage measurement.

4 Turn on ignition.

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Measurement points

Nominal value

1-2

Battery voltage x 0.8

167

30-2 Fault Tracing

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.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

Measurement points

Nominal value

2 - Battery negative

R≈0Ω

Checking the coolant switch Tools: 88890074 Multimeter 1 Undo the connector and remove the switch from 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 multimeter 88890074 to do resistance measurement against the switch.

Measurement points

Nominal value

Blue conductor - Black conductor

R≈∞Ω (Coolant level is ok.)

3 Move a magnet along the switch and observe the resistance value.

168

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 the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Turn the starter key to position 1.

4 Use multimeter 88890074 for voltage 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! Cut the current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

4

9998534

Measurement points

Nominal value

4 - Battery negative*

R≈0Ω

NOTICE! Battery negative (–) on alternator or starter motor.

P0007186

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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 current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

NOTICE! Measurements are taken to eliminate a short circuit or open circuit in the engine control unit cable.

Measurement points

Nominal value

2 - Battery negative*

R ≈ 80 - 120 kΩ

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 the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

3 Turn the starter key to position 1.

4 Use multimeter 88890074 for voltage measurement.

Measurement points

Nominal value

2-4

U ≈ 2,9 V*

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 off ignition.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor 3 Use multimeter 88890074 for voltage measurement.

4 NOTICE! Turn on ignition.

Measurement points

Nominal value

1-2

U≈5V

Checking negative cable, exhaust temperature sensor Tools: 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Disconnect the connector from the sensor 3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

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Measurement points

Nominal value

1 - Battery negative

R≈0Ω

171

30-2 Fault Tracing

Checking exhaust temperature sensor Tools: 88890074 Multimeter 1 Cut the current with the main switch.

2 Undo the connector from the sensor and remove the sensor from the exhaust elbow. Check that the sensor has no visible damage.

3 Use multimeter 9812519 to measure the resistance between the two sensor contact pins. The resistance must correspond to the values in the table.

°C Ω

172

Exhaust Temperature Resistance

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30-2 Fault Tracing

Measuremen Nominal resistance value t points

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 the current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

4

9998534

Measurement points

Nominal value

4 - Battery negative*

R≈0Ω

NOTICE! * Battery negative (–) on alternator or starter motor.

P0007186

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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 the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 for voltage measurement.

4 NOTICE! Turn the starter key to position 1.

Measurement points

Nominal value

3-4

U≈5V

5 Turn off ignition.

6 Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

7 Turn on ignition.

174

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 temperature (engine).

Tools: 9998534 Break-out cable 885675 Break-out cable 88890074 Multimeter 1 NOTICE! Cut the current with the main switch.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the sensor.

Do not connect the other end of the adapter cable.

3 Use multimeter 88890074 to measure the resistance of the sensor.

Measuremen Nominal value t points

kΩ

C

P0007238

kΩ °C

Resistance Engine Oil Temperature

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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))

175

30-2 Fault Tracing

Checking negative cable, 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.

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 to do resistance measurement towards the engine control unit.

Measurement points

Nominal value

4 - Battery negative*

R≈0Ω

NOTICE! * Battery negative (–) on alternator or starter motor.

176

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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 off ignition.

(If MCC, turn main battery switches off.)

2 Disconnect the connector from the sensor Connect break-out cable 9998534 or 885675 to the cable harness connector to the engine control unit.

3 Use multimeter 88890074 for voltage measurement.

Measurement points

Nominal value

3-4

U≈5V

4 Turn off ignition.

5 Connect break-out cable 9998534 or 885675 between the sensor and engine control unit.

6 Turn on ignition.

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Measurement points

Nominal value

3-4

U ≈ 0,5 - 4,5 V (depending on the temperature)

177

30-2 Fault Tracing

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.

2 Connect break-out cable 9998534 or 885675 to the sensor. Do not connect the other end of the adapter cable.

3 Use multimeter 88890074 to do resistance 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

C

P0007238

kΩ °C

178

Resistance Engine Oil Temperature

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30-2 Fault Tracing

Checking the starter motor solenoid Tools: 88890074 Multimeter 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Undo the red/yellow cable.

3 Use multimeter 88890074 to do resistance measurement towards the relay.

Nominal value R ≈ 2-12 Ω* NOTICE! * Depending on whether the engine is equipped with 12 V or 24 V. A

Measurement points

Checking the pre-start relay 1 NOTICE! Turn the starter key to position 0.

(If MCC, turn main battery switches off.)

2 Access the fuses by removing the cover.

3 Identify the pre-start relay.

4 Remove the relay from its protective box.

5 Undo the relay from the relay socket.

6 Measure the resistance between pins 85 and 86 on the relay. Check that there is no short circuit or open circuit.

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30-2 Fault Tracing

Checking the external stop voltage potential Tools: 9990014 Break-out cable 9998699 Break-out box 88890074 Multimeter 1 Turn off ignition (If MCC, turn main battery switches off.)

2 Cut the current with the main switch.

3 Connect 9998699 Break-out box and 9990014 Break-out cable as described in section Connection of 9998699 Break-out box to EMS 2 in chapter Repair Instructions.

4 Turn on main switch.

5 Turn on ignition 6 Use multimeter 88890074 for voltage measurement.

Measurement points

Nominal value

Pin A27 for the EMS2 (color: green) - Battery negative terminal

U ≈ 0.8 x Battery voltage (stop not activated)

Pin A27 for the EMS2 (color: green) - Battery negative terminal

U ≈ Battery voltage (stop activated)

180

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37-0 Wiring Diagrams

37-0 Wiring Diagrams NOTICE! Please refer to publ. no. 47702819.

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181

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 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.

182

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39-0 General

Checking propeller rotation ZF311 and ZF325

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”.

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 5

3 4

IMPORTANT! Check that the trolling valve cable is correctly connected to the trolling valve*.

NOTICE! * Only reversing gear ZF311 and ZF325 can be equipped with an electrically controlled trolling valve for the low speed or trolling function (optional).

1 Oil pressure- /oil temperature sensor 2 Primary solenoid valve 3 Slip valve

P0008761

4 Secondary solenoid valve The illustration shows the reversing gear with trolling valve and cables connected for left-hand rotation.

Twin Disc MG5114DC

5 Cable marking ”SECONDARY” 6 Cable marking “PRIMARY”

1 Primary solenoid valve 2 Cable marking “PRIMARY”

4

3 Cable marking ”SECONDARY”

1 3 2

4 Secondary solenoid valve

P0008762

The illustration shows the cables connected for left-hand rotation.

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183

39-0 General

Index MID 128: Engine control unit Caption

PID

PPID SID

PSID FMI

MID 128, PID 20, Extended Range Engine Coolant Pressure 20

1, 3, 5

MID 128, PID 94 Fuel Delivery Pressure

94

1, 3, 5, 7

MID 128, PID 97 Water in fuel indicator

97

0, 3

MID 128, PID 98 Engine oil level

98

1, 3

MID 128, PID 100 Engine oil pressure

100

1, 3, 5

MID 128, PID 105 Intake manifold temperature

105

0, 4, 5

MID 128, PID 106 Air inlet pressure

106

0, 3, 5

MID 128, PID 110 Engine coolant temperature

110

0, 4, 5

MID 128, PID 111 Coolant level

111

1, 3

MID 128, PID 153 Crankcase pressure

153

0, 3, 5

MID 128, PID 158 ECU battery potential

158

1

MID 128, PID 163, Transmission range attained

163

9

MID 128, PID 173 Exhaust gas temperature

173

0, 4, 5

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

175

0, 4, 5

Engine Oil Temperature (D16)

175

0, 4, 5

MID 128, PID 190 Engine speed

190

0

MID 128, PPID 3 Starter Output

3

3, 4, 5

MID 128, PPID 6 Key off input sensor

6

4, 11

MID 128, PPID 8 Piston Cooling Oil Pressure (D9, D12, D16)

8

1

Piston cooling oil pressure (D11)

8

1, 3, 5

MID 128, PPID 98 Engine sync acknowledge

98

9

MID 128, PPID 117 Engine protection status

117

7

MID 128, PPID 132 Throttle Calibrated Position

132

9

MID 128, PPID 267, Sea water pressure

267

1, 3, 5

MID 128, SID 1/2/3/4/5/6 Injector # 1-6

1/2/3/4/5/6

3, 4, 5, 7, 12

MID 128, SID 21 Engine position

21

2, 3, 8

MID 128, SID 22 Timing sensor, crank

22

2, 3, 8

MID 128, SID 32, Wastegate output driver

32

3, 4, 5

MID 128, SID 89 Air Compressor Actuator Circuit

89

3, 4, 5

MID 128, SID 232 5 V supply

232

3, 4

MID 128, SID 240 Program memory

240

2

MID 128, SID 254 Controller 1

254

3, 12

MID 128, SID 231 SAE J1939 data link

231

2, 9

MID 128, PSID 112 Exhaust Manifold Water Temperature Sensor #1

112

0, 3, 4, 5

MID 128, PSID 216 Data Link, MID187

216

9

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39-0 General

MID 158: Power module Caption

PSID

FMI

MID 158, PSID 1, Primary battery circuit

1

3, 4

MID 158, PSID 2, Secondary battery circuit

2

3, 4

MID 158, PSID 4, 30 supply fuse

4

6

MID 158, PSID 5, EMS supply fuse

5

5, 6

MID 158, PSID 6, Extra supply fuse

6

6

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185

Index A About this Workshop manual..................................... 2 Adjustment parameters for low-speed or trolling function................................................................... 182 C Checking camshaft sensor..................................... 148 Checking exhaust temperature sensor................... 172 Checking flywheel sensor....................................... 145 Checking negative cable, air inlet pressure sensor 163 Checking negative cable, coolant pressure sensor 140 Checking negative cable, coolant switch................ 168 Checking negative cable, coolant temperature sensor..................................................................... 165 Checking negative cable, crankcase pressure sensor..................................................................... 169 Checking negative cable, exhaust temperature sensor..................................................................... 171 Checking negative cable, fuel pressure sensor...... 142 Checking negative cable, intake manifold temperature sensor................................................ 155 Checking negative cable, oil level switch............... 149 Checking negative cable, oil temperature sensor............................................................. 173, 176 Checking negative cable, piston cooling pressure sensor.............................................. 160, 161 Checking negative cable, seawater pressure sensor..................................................................... 158 Checking negative cable, water switch, fuel filter... 146 Checking power supply cable, oil temperature sensor..................................................................... 174 Checking power supply cable, piston cooling pressure sensor.............................................. 161, 162 Checking propeller rotation.................................... 183 Checking signal cable, air inlet pressure sensor.... 163 Checking signal cable, coolant pressure sensor.... 141 Checking signal cable, coolant temperature sensor 166 Checking signal cable, crankcase pressure sensor 170 Checking signal cable, exhaust temperature sensor..................................................................... 171 Checking signal cable, fuel pressure sensor.......... 143 Checking signal cable, intake manifold temperature sensor................................................ 155 Checking signal cable, oil pressure sensor............ 157 Checking signal cable, oil temperature sensor....... 177 Checking signal cable, seawater pressure sensor. 159 Checking signal cable, water switch, fuel filter....... 146 Checking supply cable, air inlet pressure sensor... 164 Checking supply cable, coolant pressure sensor... 140 Checking supply cable, coolant switch................... 167 Checking supply cable, crankcase pressure sensor..................................................................... 169 Checking supply cable, fuel pressure sensor......... 142 Checking supply cable, oil level switch.................. 149 Checking supply cable, oil pressure sensor........... 157 Checking supply cable, seawater pressure sensor 159 Checking supply cable, water switch, fuel filter...... 145 Checking the air inlet pressure sensor................... 164 Checking the coolant pressure sensor................... 141 Checking the coolant switch................................... 168 47700583 08-2019 © AB VOLVO PENTA

Checking the coolant temperature sensor.............. 167 Checking the crankcase pressure sensor.............. 170 Checking the external stop voltage potential.......... 180 Checking the fuel pressure sensor......................... 143 Checking the injector coils...................................... 153 Checking the intake manifold temperature sensor. 156 Checking the oil level sensor.................................. 151 Checking the oil level switch.................................. 150 Checking the oil pressure sensor........................... 158 Checking the oil temperature sensor.............. 175, 178 Checking the piston cooling pressure sensor......... 162 Checking the pre-start relay................................... 179 Checking the seawater pressure sensor................ 160 Checking the starter motor solenoid....................... 179 Checking the wastegate valve................................ 144 Checking the water in fuel switch, fuel filter........... 147 Component description............................................ 27 Component location................................................. 17 D Design and Function.......................................... 17, 43 E Engine Protection Map............................................... 9 F Fault Codes.............................................................. 59 Fault Tracing............................................................ 59 Function fault............................................................ 57 G General......................................................... 2, 17, 182 I Index....................................................................... 184 Injector trim............................................................. 152 M Measurements........................................................ 140 MID 128, PID 100 Engine oil pressure..................... 71 MID 128, PID 105 Intake manifold temperature....... 74 MID 128, PID 106 Air inlet pressure......................... 77 MID 128, PID 110 Engine coolant temperature........ 80 MID 128, PID 111 Coolant level............................... 83 MID 128, PID 153 Crankcase pressure.................... 85 MID 128, PID 158 ECU battery potential.................. 88 MID 128, PID 163, Transmission range attained..... 89 MID 128, PID 173 Exhaust gas temperature............ 90 MID 128, PID 175 Engine oil temperature.......... 92, 95 MID 128, PID 190 Engine speed.............................. 98 MID 128, PID 20, Extended Range Engine Coolant Pressure...................................................... 59 MID 128, PID 94 Fuel Delivery Pressure................. 61 MID 128, PID 97 Water in fuel indicator................... 64 MID 128, PID 98 Engine oil level.............................. 68 MID 128, PPID 117 Engine protection status......... 107 MID 128, PPID 132 Throttle Calibrated Position.... 108 MID 128, PPID 267, Sea water pressure............... 109 MID 128, PPID 3 Starter Output............................... 99 MID 128, PPID 6 Key off input sensor.................... 100 MID 128, PPID 8 Piston Cooling Oil Pressure 102, 105 MID 128, PPID 98 Engine sync acknowledge........ 106

187

MID 128, PSID 112 Exhaust Manifold Water Temperature Sensor #1......................................... 131 MID 128, PSID 216 Data Link, MID187.................. 133 MID 128, SID 1/2/3/4/5/6 Injector # 1-6.................. 111 MID 128, SID 21 Engine position........................... 115 MID 128, SID 211 Sensor Supply Voltage #2 (+5 V DC)................................................................. 66 MID 128, SID 22 Timing sensor, crank.................. 118 MID 128, SID 231 SAE J1939 data link................. 130 MID 128, SID 232 5 V supply................................. 127 MID 128, SID 240 Program memory...................... 128 MID 128, SID 253 Calibration memory EEPROM ... 67 MID 128, SID 254 Controller 1............................... 129 MID 128, SID 32, Wastegate output driver............. 122 MID 128, SID 89 Air Compressor Actuator Circuit. 125 MID 158, PSID 1, Primary battery circuit................ 134 MID 158, PSID 2, Secondary battery circuit........... 135 MID 158, PSID 4, 30 supply fuse........................... 136 MID 158, PSID 5, EMS supply fuse....................... 137 MID 158, PSID 6, Extra supply fuse....................... 139 R Repair Instructions................................................... 46 Repair instructions...................................................... 3 S Safety Information.................................................... 10 Safety Instructions.................................................... 10 Special Service Tools............................................... 15 Specifications, Electrical............................................. 5 Switches and Senders................................................ 5 W Wiring Diagrams..................................................... 181

188

References to Service Bulletins Group No.

Date

Refers to

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08-2019