Workshop Manual D9,d11,d12,d13,d16 Marine Engine 5p3210

Workshop Manual Group 30 Electrical system

E 2(0)

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

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

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

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

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

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

Cables and fuses 37-0 Wiring Diagrams ......................................................................... 196

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

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08-2017 © AB VOLVO PENTA

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.

2

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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 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.

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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3

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 ts 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 ts 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 ts, 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. 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

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


-40 °C to +130 °C (-40 °F to +266 °F)

Type

Inductive sensor


8 ±2 Nm (5.9 ±1.5 lbf.ft.)

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

5V

Connector

4 pin


0–700 kPa (0–7 bar / 0–102 PSI)

Pressure signal

0.5–4.5 V


-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear/NTC


30 ±5 Nm (22.1 ±3.7 lbf.ft.)

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

5V

Connector

4 pin


-40 °C to +140 °C (-40 °F to +284 °F)

Type

NTC

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5


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

5V

Connector

4 pin


0–3 MPa (0–30 bar / 0–435 PSI)

Pressure signal

0.5–4.5 V


-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


40–400 kPa (0.4–4 bar / 5.8–58 PSI)

Pressure signal

0.5–4.5 V


-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


50–600 kPa (0.5–6 bar / 7.3–87 PSI)

Pressure signal

0.5–4.5 V


-40 °C to +125 °C (-40 °F to +257 °F)

Type

Linear/NTC

Sensor, coolant temperature Voltage

5V

Connector

2 pin


-40 °C to +150 °C (-40 °F to +302 °F)

Type

NTC


28 Nm (20.7 lbf.ft)

Sensor, crankcase pressure Voltage

5V

Connector

3 pin


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

Pressure signal

0.5–4.5 V


-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear

6

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Sensor, seawater pressure Voltage

5V

Connector

3 pin


0–300 kPa (0-3 bar / 0-43.5 PSI)

Pressure signal

0.5–4.5 V


-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear

Sensor, coolant pressure Voltage

5V

Connector

3 pin


0–300 kPa (0-3 bar / 0-43.5 PSI)

Pressure signal

0.5–4.5 V


-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear

Sensor, piston cooling pressure Voltage

5V

Connector

3 pin


0–700 kPa (0–7 bar / 0–102 PSI)

Pressure signal

0.5–4.5 V


-40 °C to +140 °C (-40 °F to +284 °F)

Type

Linear


25 ±3 Nm (18.4 ±2.2 lbf.ft.)

Switch, coolant level Connector

2 pin

type

Closing for low coolant level

Switch, piston cooling pressure Connector

2 pin

type

Closing for low piston cooling pressure

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7


Switch, oil level (D9, D12) Connector

2 pin

type

Closing for low oil level

Wastegate valve Operational voltage

20–32 V

Connector

2 pin


0–300 kPa (0-3 bar / 0-43.5 PSI)

Pressure signal

0.5–4.5 V


-30 °C to +130 °C (-22 °F to +266 °F)

Coil resistance

90 ± 4.5 Ω at 20 °C (68 °F)

Alternator Voltage

14 / 28 V

Connector

2 pin

Capacity

115 A at 14 V / 80 A at 28 V

Starter motor Voltage

12 / 24 V

Connector

2 pin

Capacity (applies to D9)

5.5 kW at 12/24 V


5.5 kW at 24 V

Capacity (applies to D12, D13)

6.0 kW at 24 V


7.0 kW at 24 V

8

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

D9 Propulsion Sensors Control and monitoring system Sensors

Switches Engine Shutdown System

Signal

Range

Warning Initial Delay / Warning Delay

Warning level

Derating level

Shutd. Initial Delay / Shutd. Delay

Shutdow n level (Toleranc e)

Air inlet pressure

0.5-4.5 V

50-400 kPa (7-58 psi)

30 sec from start / 3 sec

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

335 kPa (49 psi) 50% derating.

NA

NA

Intake manifold temperature

50-0 Ω

-40 - 130 °C ±4% (-40 - 266 °F ±4%)


80 °C (176 °F)

90 °C (194 °F) Soft derate.

NA

NA

Coolant level switch

Digital

ON/OFF


Low (On / Closed)

NA

NA

NA

Coolant temperature

50-0 Ω

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


98 °C (208.4 °F)

101 °C (213.8 °F) Soft derate.

1 sec

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

NA

NA

NA

Rapid pressure increase

75% derating, 100 rpm

NA

NA

Engine speed, camshaft

Freque ncy

-

Instant

Lost signal

NA

NA

NA

Engine speed, crankshaft

Freque ncy

-

Instant

Lost signal

NA

NA

NA

Eng. overspeed SDU 1800+15%

Freque ncy

54 puls./rev.

Instant

Lost signal

NA

Instant

2070 / 1863 Hz (-1 to 0%)


Freque ncy

54 puls./rev.

Instant

Lost signal

NA

Instant

2530 / 2277 Hz (-1 to 0%)

Exhaust gas temperature after turbine

PT200

0-850 °C ±2.5% (0-1562 °F ±2.5%)

30 sec from start / 1.5 sec

600 °C (1112 °F)

620 °C (1148 °F) Soft derate.

NA

NA

Oil level sensor

Digital

ON/OFF


Low level

NA

NA

NA

Crankcase pressure

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9


Sensors Control and monitoring system


Sensors

Signal

Range


Warning level

Derating level



Oil temperature

50-0 Ω

-40 - 140 °C (-40 - 284 °F


125 °C (257 °F)

128 °C (262.4 °F) Soft derate.

NA

NA

Piston cooling switch

Digital

ON/OFF

Instant after 1000 rpm

120 ±20 kPa (17.4 ±2.9 psi)

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

NA

NA

Water in fuel switch

Digital

ON/OFF

Always

Water in fuel

NA

NA

NA

D9 Propulsion Sensors (rpm Signal dependent) Coolant Pressure

Range

0.5-4.5 0-300 kPa V ±3% (0-43.5 psi ±3%)

Initial Delay / Delay

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

Switches Shutdown System

-

0 rpm

500 rpm

1000 rpm

1800 rpm

2200 rpm

-

Warning level

-

-


0

0

20 (2.9)

50 (7.3)

70 (10.2)

-

Derating level

-

-

10% trq. decr./sec

0

0

10 (1.5)

40 (5.8)

60 (8.7)

-

Differential oil pressure

NA

NA

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-

NA

NA

NA

NA

NA

NA

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

-

0 rpm

600 rpm

1000 rpm

1800 rpm

2200 rpm

-

Fuel pressure 0.5-4.5 0-700 kPa V ±1.5% (0-102 psi ±1.5%) Warning level

-

-


100 (14.5)

100 (14.5)

150 (21.8)

250 (36.3)

250 (36.3)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

10

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Sensors (rpm Signal dependent) Oil pressure

Range


0.5-4.5 0-700 kPa V ±1.5% (0-102 psi ±1.5%)

-

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

500 rpm


1000 rpm

1800 rpm

2300 rpm

-

Warning level

-

-


-100 170 (-14.5) (24.7)

200 (29.0)

225 (32.6)

250 (36.3)

-

Derating level

-

-

10% trq. decr./sec

-120 150 (-17.4) (21.8)

180 (26.1)

205 (29.7)

205 (29.7)

-

Shutdown level (Shutd. Unit Ch. S3)

Digital

ON/OFF

11 sec ±20% from start / 1 sec

NA

NA

120 +20 (17.4 +2.9)

120 +20 (17.4 +2.9)

120 +20 (17.4 +2.9)

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

Seawater pressure

0.5-4.5 0-300 kPa V ±3% (0-44 psi ±3%)

-

0 rpm

600 rpm

1400 rpm

1700 rpm

1900 rpm

-

Warning level

-

-


0

5 (0.7)

10 (1.4)

15 (2.2)

20 (2.9)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

Rev. gear pressure

-

-

-

0 rpm

600 rpm

1300 rpm

1500 rpm

1800 rpm

-

Warning level

NA

NA

NA

NA

NA

NA

NA

NA

-

Derating level

NA

NA

NA

NA

NA

NA

NA

NA

-

Digital

ON/OFF


NA

400 +20 (58.0 +2.9)

400 +20 (58.0 +2.9)

400 +20 (58.0 +2.9)

400 +20 (58.0 +2.9)



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11


D9 MG Sensors Control and monitoring system Sensors


Signal

Range


Warning level

Derati ng level



Air inlet pressure

0.5-4.5 V

50-400 ±4.2 kPa (7-58 ±0.6 psi)


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

NA

NA

NA


50-0 Ω

-40 - 130 °C ±4% (-40 - 266 °F ±4%)


80 °C (176 °F)

NA

NA

NA


Digital

ON/OFF


Low (On / Closed)

NA

NA

NA

Coolant temperature

50-0 Ω

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


98 °C (208.4 °F)

NA

1 sec

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


Freque ncy

-

Instant

Lost signal

NA

NA

NA


Freque ncy

-

Instant

Lost signal

NA

NA

NA


Freque ncy

54 puls./rev.

Instant

Lost signal

NA

Instant

1725 / 1553 Hz (-1 to 0%)


Freque ncy

54 puls./rev.

Instant

Lost signal

NA

Instant

2070 / 1863 Hz (-1 to 0%)

Exhaust gas temperature after turbine

PT200

600 °C (1112 °F)

NA

NA

NA

Oil level sensor

Digital

ON/OFF


Low level

NA

NA

NA

Oil temperature

50-0 Ω

-40 - 140 °C (-40 - 284 °F


125 °C (257 °F)

NA

NA

NA


Digital

ON/OFF

Instant after 1000 rpm

120 ±20 kPa (17.4 ±2.9 psi)

NA

NA

NA


Digital

ON/OFF

Always

Water in fuel

NA

NA

NA

12

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

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D9 MG Sensors (rpm Signal dependent) Coolant Pressure

Range


0.5-4.5 0-300 kPa V ±3% (0-43.5 psi ±3%)



-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-


0

0

20 (2.9)

50 (7.3)

70 (10.2)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-


NA

NA

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-

NA

NA

NA

NA

NA

NA

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

-

0 rpm

600 rpm

1000 rpm

1600 rpm

1800 rpm

-

Fuel pressure 0.5-4.5 0-700 kPa V ±1.5% (0-102 psi ±1.5%) Warning level

-

-


0

100 (14.5)

200 (29.0)

300 (43.5)

300 (43.5)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

-

0 rpm

500 rpm

1000 rpm

1800 rpm

2300 rpm

-

Oil pressure

0.5-4.5 0-700 kPa V ±1.5% (0-102 psi ±1.5%)

Warning level

-

-


0

160 (23.2)

200 (29.0)

225 (32.6)

250 (36.3)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-


Digital

ON/OFF


NA

NA

120 +20 (17.4 +2.9)

120 +20 (17.4 +2.9)

120 +20 (17.4 +2.9)


Seawater pressure

0.5-4.5 0-300 kPa V ±3% (0-44 psi ±3%)

-

0 rpm

600 rpm

1400 rpm

1700 rpm

1900 rpm

Only HE and KC

Warning level

-

-


0

5 (0.7)

10 (1.4)

15 (2.2)

20 (2.9)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

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13


D11 Propulsion Derate to engine protection map Parameter

“Yellow lamp”

“Red lamp”

Derating

High coolant temperature

98 °C (208 °F)

101 °C (213.8 °F)

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

High oil temperature

120 °C (248 °F)

122 °C (251.6 °F)

122 °C (251.6 °F) –0% 124 °C (255.2 °F) –50% 126° (258.8 °F) –70%

High intake manifold temperature

75 °C (167 °F)

80 °C (176 °F)

80 °C (176 °F) –0% 85 °C (185 °F) –50% 90 °C (194 °F) –70%

High air inlet pressure

270 kPa (39.2 PSI)

280 kPa (40.6 PSI)

>280 kPa (40.6 PSI) –50%

Low coolant level

Switch

-

-

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

0 kPa (0 PSI)

500 rpm

160 kPa (23.2 PSI)

1 000 rpm

280 kPa (40.6 PSI)

1500 rpm

320 kPa (46.4 PSI)

2300 rpm

330 kPa (47.9 PSI)

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

0 kPa (0 PSI)

800 rpm

0 kPa (0 PSI)

1000 rpm

75 kPa (10.9 PSI)

1500 rpm

230 kPa (33.4 PSI)

2300 rpm

250 kPa (36.3 PSI)

Derate 75% on pressures lower than the map value.

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

14

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D12 Propulsion Sensors Warning / Alarm

Alarm level

Derating level

Condition/delay

Derating


80 °C (176 °F)

85 °C (185 °F)

-

Soft derate

Coolant temperature

95 °C (203 °F)

98 °C (208.4 °F)

-

-

Crankcase pressure

Rapid pressure increase

-

-

1000 rpm

Oil temperature

125°C (257 °)

128°C (262,4 °F) 128°C (262.4 °F)

-

-

Piston cooling pressure

150 ±20 kPa (21.8 ±2.9 PSI)

150 ±20 kPa (21.8 ±2.9 PSI)

Above 1300 rpm instant

Yes, 70%

Water in fuel

Water in fuel

-

-

-

Sensors Warning / Alarm

Rpm map

Air inlet pressure

1700 rpm

1900 rpm

2100 rpm

2300 rpm

2360 rpm

-

Alarm level

450 kPa (65.3 PSI)

440 kPa (63.8 PSI)

430 kPa (62.4 PSI)

395 kPa (57.3 PSI)

390 kPa (56.6 PSI)

-

Derating limit

460 kPa (66.7 PSI)

450 kPa (65.3 PSI)

440 kPa (63.8 PSI)

405 kPa (58.7 PSI)

400 kPa (58.0 PSI)

Yes, 50%

Fuel pressure

500 rpm

1800 rpm

2300 rpm

-

-

-

Alarm level

50 kPa (7.3 PSI)

200 kPa (29.0 PSI)

200 kPa (29.0 PSI)

-

-

-

Oil pressure

500 rpm

1000 rpm

1800 rpm

2300 rpm

-

-

Alarm level

150 kPa (21.8 PSI)

200 kPa (29.0 PSI)

225 kPa (32.6 PSI)

250 kPa (36.3 PSI)

-

-

Derating limit

130 kPa (18.9 PSI)

170 kPa (24.7 PSI)

205 kPa (29.7 PSI)

230 kPa (33.4 PSI)

-

Yes, 70%

47700583

Derating


15


D13 Propulsion Sensors Warning / Alarm

Alarm level

Derating level

Derating

Coolant level

Low (ON / closed)

-

-

Coolant temperature

98 °C (218.4 °F)

101 °C (213.8 °F)

See soft derate 1

Coolant temperature, SDU

N/A

N/A

N/A


Lost signal

N/A

N/A

Engine speed, crank

Lost signal

N/A

N/A

Engine overspeed SDU 2300 + 15% Lost signal

N/A

N/A

Exhaust wet gas temperature

200 °C (392 °F)

See soft derate 2

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

585 °C (1085 °F)

See soft derate 2

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

670 °C (1238 °F)

See soft derate 3

Oil level

Low level

N/A

N/A

Oil temperature

130 °C (266 °F)

135 °C (275 °F)

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


N/A

N/A

N/A

Gear oil temperature, EVC (D13BC/G)

95 °C (203 °F)

N/A

N/A

Gear oil temperature, EVC (D13BD)

N/A

N/A

N/A

Gear oil pressure, EVC

700 kPa (101.5 PSI) N/A

N/A

Gear oil pressure, SDU

N/A

N/A

N/A

Intake manifold temperature (D13B-D MP)

80 °C (176 °F)

85 °C (185 °F)

See soft derate 2

Crankcase pressure

N/A

N/A

N/A

Water in fuel

Water In fuel

N/A

N/A

175 °C (347 °F)

Switches Engine Shutdown System Switches

Range

Shutd.. Initial Delay / Shutd. Delay

Shutdown Level (Tolerance)

Coolant temperature, SDU

ON/OFF


SDU S1: 105 ±2 °C (221 ±3.6 °F)

Engine overspeed SDU 2300 + 15% 153 puls./rev.

Instant

2645 / 6745 Hz (-1 to 0%)

Gear oil pressure, SDU


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

16

ON/OFF

47700583



D13 Propulsion Sensors Warning / Alarm / Derating

Rpm map

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

600 rpm

1000 rpm

1500 rpm

2000 rpm

2300 rpm

Warning level 0 % load

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

-


420 kPa (60.9 PSI)

268 kPa (38.9 PSI)

295 kPa (42.8 PSI)

333 kPa (48.3 PSI)

345 kPa (50.0 PSI)

-

Derating level 100 % load

430 kPa (62.4 PSI)

278 kPa (40.3 PSI)

305 kPa (44.2 PSI)

343 kPa (49.7 PSI)

355 kPa (51.5 PSI)

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

Air inlet pressure (D13B-G R5 900 hp)

600 rpm

1000 rpm

1500 rpm

2000 rpm

2300 rpm


420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

420 kPa (60.9 PSI)

-


420 kPa (60.9 PSI)

322 kPa (611.6 PSI)

335 kPa (635.0 PSI)

356 kPa (672.8 PSI)

366 kPa (690.8 PSI)

-

Derating level 100 % load

430 kPa (62.4 PSI)

332 kPa (629.6 PSI)

345 kPa (653 PSI)

366 kPa (690.8 PSI)

376 kPa (708.8 PSI)


Air inlet pressure (D13B-D R3 700hp)

600 rpm

1000 rpm

1500 rpm

2000 rpm

2300 rpm

Warning level

305 kPa (44.2 PSI)

305 kPa (44.2 PSI)

305 kPa (44.2 PSI)

295 kPa (42.8 PSI)

259 kPa (37.6 PSI)

-

Derating level

315 kPa (45.7 PSI)

315 kPa (45.7 PSI)

315 kPa (45.7 PSI)

305 kPa (44.2 PSI)

269 kPa (39.0 PSI)


Intake manifold temperature (D13B-C/G)

600 rpm

1000 rpm

1500 rpm

2000 rpm

2300 rpm

Warning level

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

Derating level

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

Fuel pressure

600 rpm

1000 rpm

1200 rpm

1400 rpm

2300 rpm

Warning level

180 kPa (26.1 PSI)

240 kPa (34.8 PSI)

255 kPa (37.0 PSI)

270 kPa (39.2 PSI)

270 kPa (39.2 PSI)

47700583

Condition


-

17


Oil pressure (D13B-C/G)

500 rpm

1000 rpm

1500 rpm

2300 rpm

Warning level

120 kPa (17.4 PSI)

200 kPa (29.0 PSI)

265 kPa (38.4 PSI)

265 kPa (38.4 PSI)

-

Derating level

90 kPa (13.1 PSI)

170 kPa (24.7 PSI)

235 kPa (34.1 PSI)

235 kPa (34.1 PSI)

-

Shutdown level (Shutdown N/A Unit Channel S3)

N/A

150 ±20 kPa (21.8 ±2.9 PSI)

150 ±20 kPa (21.8 ±2.9 PSI)

150 ±20 kPa (21.8 ±2.9 PSI)

Oil pressure (D13B-D)

0 rpm

600 rpm

1000 rpm

1500 rpm

2300 rpm

Warning level

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

200 kPa (29.0 PSI)

265 kPa (38.4 PSI)

265 kPa (38.4 PSI)

-

Derating level

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

170 kPa (24.7 PSI)

235 kPa (34.1 PSI)

235 kPa (34.1 PSI)

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

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

Shutdown level (Shutdown N/A Unit Channel S3)

N/A

150 ±20 kPa (21.8 ±2.9 PSI)

150 ±20 kPa (21.8 ±2.9 PSI)

150 ±20 kPa (21.8 ±2.9 PSI)

Coolant pressure (D13B-C/D)

0 rpm

600 rpm

1000 rpm

1500 rpm

2300 rpm

Warning level

0 kPa (0.0 PSI)

5 kPa (0.7 PSI)

30 kPa (4.4 PSI)

55 kPa (8.0 PSI)

125 kPa (18.1 PSI)

-

Derating level

-10 kPa (-1.5 PSI)

-5 kPa (-0.7 PSI)

20 kPa (2.9 PSI)

45 kPa (6.5 PSI)

115 kPa (16.7 PSI)

-

Seawater pressure (D13B-C/D)

600 rpm

1000 rpm

1500 rpm

1900 rpm

2300 rpm

Warning level

5 kPa (0.7 PSI)

20 kPa (2.9 PSI)

40 kPa (5.8 PSI)

60 kPa (8.7 PSI)

60 kPa (8.7 PSI)

-

Derating level

-5 kPa (-0.7 PSI)

10 kPa (1.5 PSI)

30 kPa (4.4 PSI)

50 kPa (7.3 PSI)

50 kPa (7.3 PSI)

-

18

47700583



Soft derate, D13 1) Soft derate, coolant temp

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

Remaining torque

1200 rpm

100 %

100 %

100 %

1800 rpm

100 %

75 %

50 %

2300 rpm

100 %

75 %

50 %

2) Soft derate, exhaust gas temp

Speed / °C 585°C (1085 °F)

590°C (1094 °F)

595°C (1103 °F)

600°C (1112 °F)

D13B-C/G Remaining torque

1200 rpm

100 %

100 %

100 %

100 %

1800 rpm

100 %

70 %

60 %

50 %

2300 rpm

100 %

70 %

60 %

50 %

2) Soft derate, intake manifold temp

Speed / °C 85 °C (185 °F)

90 °C (194 °F)

95 °C (203 °F)

D13B-D Remaining torque

1200 rpm

100 %

96 %

94 %

1800 rpm

100 %

50 %

30 %

2300 rpm

100 %

50 %

30 %

3) Soft derate, oil temp

Speed / °C 135 °C (275 °F)

137 °C (278.6 °F) 139 °C (282.2 °F)


600 rpm

100 %

100 %

100 %

1200 rpm

100 %

50 %

30 %

1800 rpm

100 %

50 %

30 %

3) Soft derate, exhaust temp

Speed / °C 670 °C (1238 °F) 675 °C (1247 °F) 680 °C (1256 °F) 685 °C (1265 °F)


1200 rpm

100 %

98 %

97 %

96 %

1800 rpm

100 %

70 %

60 %

50 %

2300 rpm

100 %

70 %

60 %

50 %

4) Soft derate, intake manifold temp

Speed / °C 70 °C (158 °F) Varvtal

75 °C (167 °F)

80 °C (176 °F)

85 °C (185 °F)


1200 rpm

100%

100%

100%

100%

1500 rpm

100%

100%

100%

100%

1800 rpm

100%

100%

60 %

34 %

2000 rpm

100%

50 %

30 %

30 %

2300 rpm

100%

50 %

30 %

30 %

90 °C (194 °F)

95 °C (203 °F)

1200 rpm

100%

100%

1500 rpm

50 %

30 %

1800 rpm

30 %

30 %

2000 rpm

30 %

30 %

2300 rpm

30 %

30 %


Speed / °C 135 °C (275 °F)

137 °C (278.6 °F) 139 °C (282.2 °F)


1200 rpm

100 %

100 %

100 %

1800 rpm

100 %

50 %

30 %

2300 rpm

100 %

50 %

30 %

47700583


19


D16 Propulsion Sensors Control and monitoring system Sensors

Signal

Range

Air inlet pressure

0.5-4.5 V

50-400 kPa (7-58 psi)

Air inlet pressure after turbine

50-0 Ω



Shutdo wn level (Toleran ce)

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

NA

NA

-40 - 130 °C ±4% (-40 - 266 °F ±4%)


80 °C (176 °F)

90 °C (194 °F) See soft derate 3.

NA

NA

Digital

ON/OFF


Low (On / Closed)

NA

NA

NA

Coolant temperature

50-0 Ω

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


98 °C (208.4 °F)

101°C (213.8 °F) See soft derate 1.

1 sec

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


Freque ncy

-

Instant

Lost signal

NA

NA

NA


Freque ncy

-

Instant

Lost signal

NA

NA

NA


Freque ncy

153 puls./rev.

Instant

Lost signal

NA

Instant

2070 / 5279 Hz (-1 to 0%)


Freque ncy

153 puls./rev.

Instant

Lost signal

NA

Instant

2185 / 5572 Hz (-1 to 0%)

Exhaust Temperature

PT200

0-850 °C (0-1562 °F)


650 °C (1202 °F)

665 °C (1229 °F) See soft derate 4.

NA

NA

Oil level sensor

Digital

ON/OFF


Low level

NA

NA

NA

20



Warning level

Derating level

47700583



Sensors Control and monitoring system Sensors


Signal

Range


Warning level

Derating level



Oil temperature

50-0 Ω

-40 - 140 °C (-40 - 284 °F


125 °C (257 °F)

128 °C (262.4 °F) See soft derate 2.

NA

NA


Digital

ON/OFF


120 ±20 kPa (17.4 ±2.9 psi)

120 kPa (17.4 psi) 70% derating.

NA

NA

Rev. gear temperature

NA

NA

NA

NA

NA

NA

NA


Digital

ON/OFF

Always

Water in fuel

NA

NA

NA

D16 Propulsion Sensors (rpm Signal dependent) Coolant Pressure

Range


0.5-4.5 0-300 kPa V ±3% (0-43.5 psi ±3%)



-

0 rpm

600 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-


0

5 (0.7)

55 (8.0)

100 (14.5)

130 (18.9)

-

Derating level (50% remaining trq.)

-

-

10% trq. decr./sec

-50 (-7.3)

-45 (-6.5)

5 (0.7)

50 (7.3)

80 (11.6)

-

Digital

ON/OFF


NA

NA

NA

NA

NA

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

NA

NA

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-

NA

NA

NA

NA

NA

NA

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

-

0 rpm

500 rpm

1000 rpm

1800 rpm

1900 rpm

-

Shutd. Level (Shutd. Unit Ch. S4)


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

-

-


-50 (-7.3)

50 (7.3)

75 (10.9)

200 (29.0)

200 (29.0)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

47700583


21


Sensors (rpm Signal dependent) Oil pressure

Range

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

Initial Delay / Delay -

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

500 rpm

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


1000 rpm

1500 rpm

1900 rpm

-

200 (29.0)

250 (36.3)

250 (36.3)

-

Warning level

-

-

Derating level (30% remaining trq.)

-

-

10% trq. decr./sec

-10 (-1.5)

140 (20.3)

180 (26.1)

230 (33.4)

230 (33.4)

-


Digital

ON/OFF


NA

NA

NA

NA

NA


Seawater pressure

0.5-4.5 0-300 kPa V (0-44 psi)

-

0 rpm

600 rpm

1400 rpm

1700 rpm

1900 rpm

Only HE and KC

Warning level

-

-


-20 (-2.9)

5 (0.7)

25 (3.6)

35 (5.1)

40 (5.8)

Only HE and KC

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

Rev. gear pressure

-

-

-

0 rpm

600 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

NA

NA

NA

NA

NA

NA

NA

NA

-

Derating level

NA

NA

NA

NA

NA

NA

NA

NA

-


Digital

ON/OFF


NA

400 ±20 (58 ±2.9)

400 ±20 (58 ±2.9)

400 ±20 (58 ±2.9)

400 ±20 (58 ±2.9)

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

22

47700583



D16 1) Soft derate, coolant temp

Speed

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

Remaining torque

600 rpm

100%

100%

100%

1200 rpm

100%

91%

82%

1800 rpm

100%

83%

66%


Speed

128 °C (262.4 °F) 130 °C (266 °F)

135 °C (275 °F)

Remaining torque

600 rpm

100%

100%

100%

1200 rpm

100%

91%

74%

1800 rpm

100%

83%

52%

3) Soft derate, intake manifold temp.

Speed

90 °C (194 °F)

95 °C (203 °F)

105 °C (221 °F)

Remaining torque

600 rpm

100%

100%

100%

1200 rpm

100%

82%

74%

1800 rpm

100%

66%

52%

4) Soft derate, exhaust temp

Speed

665 °C (1229 °F) 675°C (1247 °F)

680°C (1256 °F)

685°C (1265 °F)

Remaining torque

600 rpm

100%

100%

100%

100%

1200 rpm

100%

96%

93%

89%

1800 rpm

100%

93%

86%

80%

47700583


23


D16 MG Sensors Control and monitoring system Sensors

Signal

Range

Air inlet pressure

0.5-4.5 V

50-400 kPa (7-58 psi)

Air inlet pressure after turbine

50-0 Ω


Deratin g level



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

NA

NA

NA

-40 - 130 °C ±4% (-40 - 266 °F ±4%)


80 °C (176 °F)

NA

NA

NA

Digital

ON/OFF


Low (On / Closed)

NA

NA

NA

Coolant temperature

50-0 Ω

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


98 °C (208.4 °F)

NA

1 sec

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


Freque ncy

-

Instant

Lost signal

NA

NA

NA


Freque ncy

-

Instant

Lost signal

NA

NA

NA


Freque ncy

153 puls./rev.

Instant

Lost signal

NA

Instant

1725 / 4399 Hz (-1 to 0%)


Freque ncy

153 puls./rev.

Instant

Lost signal

NA

Instant

2070 / 5279 Hz (-1 to 0%)

Exhaust Temperature

PT200

0-850 °C (0-1562 °F)


650 °C (1202 °F)

NA

NA

NA

Oil level sensor

Digital

ON/OFF


Low level

NA

NA

NA

Oil temperature

50-0 Ω

-40 - 140 °C (-40 - 284 °F


125 °C (257 °F)

NA

NA

NA


Digital

ON/OFF

NA

NA

NA


Digital

ON/OFF

NA

NA

NA

24


Switches Engine Shutdown System Warning level

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

Water in fuel

47700583



D16 MG Sensors (rpm Signal dependent) Coolant Pressure

Range


0.5-4.5 0-300 kPa V ±3% (0-43.5 psi ±3%)



-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-


Digital

ON/OFF


NA

NA

NA

NA

NA


NA

NA

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1800 rpm

-

Warning level

-

-

NA

NA

NA

NA

NA

NA

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

-

0 rpm

600 rpm

1000 rpm

1500 rpm

1800 rpm

-


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

-

-


-50 (-7.3)

50 (7.3)

75 (10.9)

175 (25.4)

200 (29.0)

-

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

-

0 rpm

500 rpm

1000 rpm

1500 rpm

1900 rpm

-

250 (36.3)

250 (36.3)

250 (36.3)

-

Oil pressure

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

Warning level

-

-

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

Derating level

-

-

NA

NA

NA

NA

NA

NA

-


Digital

ON/OFF


NA

NA

NA

NA

NA


Seawater pressure

0.5-4.5 0-300 kPa V (0-44 psi)

-

0 rpm

600 rpm

1400 rpm

1700 rpm

1900 rpm

Only HE and KC

Warning level

-

-


-20 (-2.9)

5 (0.7)

25 (3.6)

35 (5.1)

40 (5.8)

Only HE and KC

Derating level

-

-

NA

NA

NA

NA

NA

NA

-

47700583


25

05-1 Safety Instructions

05-1 Safety Instructions Safety Information This Service Manual contains repair instructions, descriptions and technical data for products or product designs from Volvo Penta. Ensure that you are using the correct service manual.

Read the safety information below and the service manual section About this Workshop manual and Repair instructions carefully before repair and service work is begun.

! This symbol is used in the service manual and on the product, to call attention to the fact that this is safety information. Always read such information very carefully. Safety texts in the manual have the following order of priority:

DANGER! Indicates a hazardous situation, which, if not avoided, result in death or serious injury.

WARNING! Indicates a hazardous situation, which, if not avoided, could result in death or serious personal injury.

CAUTION! Indicates a hazardous situation, which, if not avoided, could result in minor or moderate personal injury. IMPORTANT! Is used to draw your attention to something that may cause minor damage or a minor malfunction to the product or property. NOTICE! Is used to draw your attention to important information that will facilitate the work or operation in progress.

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

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

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

26

47700583



!

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

!

Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out and system pressure will be lost. Open the filler cap slowly, and release the pressure in the cooling system if the filler cap or valve has to be opened, or if a plug or coolant hose has to be removed when the engine is hot.

!

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

!

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

!

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

!

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

!

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

!

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

!

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

!

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

!

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

!

Clutch adjustments must be carried out with the engine stopped.

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!

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

!

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

!

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

!

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

!

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

!

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

!

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

!

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

!

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

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

!

28

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

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!

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

!

Exercise extreme caution when leak-detecting on the fuel system and testing the fuel injector nozzles. Use eye protection. The jet from a fuel nozzle has very high pressure and great penetration power. Fuel can force its way deep into body tissue and cause severe injury. There is a risk of blood poisoning (septicemia).

!

Only use fuels and lubricating oils recommended by Volvo Penta. Refer to the Operator's Manual for the product in question. Use of fuels that are of a lower grade may damage the engine, the injection pump and the injectors. On a diesel engine, low grade fuel can cause the control rod to bind and the engine to over-rev, with the risk of engine damage and personal injury as a result. Low fuel and oil grades may result in high service, maintenance and repair costs.

!

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

!

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

!

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

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08-2 Special Service Tools

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

VODIA

1

3

4

5

75

8856

2

P0006701

885675 Break-out cable

p0005125

p0008375

88820047 VODIA, diagnostic tool Complete tool.

88890074 Multimeter

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.

Used for taking readings.

P0008793

p0005128

30

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08-2 Special Service Tools

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30-0 General

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

5

4

3

2

6

1 7

11

8 9 10

P0007164

12 13

32

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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

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 612 060 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

BROKEN

ALARMS SHUTDOWN

12

18 11


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34

WIRE

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

36

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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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P0019225

38

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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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P0019215

40

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30-0 General

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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30-0 General

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

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

Starter motor

P0007169

1

The starter motor is installed in the flywheel housing, on the right-hand side of the engine. The starter motor relay is connected between battery positive and 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.

42

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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 es 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 es through the exhaust turbine. Oil pressure is used to control the amount that the wastegate valve opens. The wastegate valve position is controlled by a solenoid that is controlled by the EMS2 The EMS2 uses a pulse width modulated signal to control the wastegate valve position.

P0010639

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30-0 General

Unit injector The unit injectors are installed on the cylinder head, underneath the valve cover. The amount of fuel injected and injection duration is controlled by the control unit, via electromagnetically controlled fuel valves in the unit injectors. This means that the engine always receives the correct volume of fuel in all operating conditions, which offers lower fuel consumption, minimal exhaust emissions etc. The unit injectors are made and classified by tolerance. Each unit injector is marked with a code on the top side of the electric connection. If an injector is replaced, the new code must be programmed for the cylinder concerned using VODIA.

Piston cooling switch (D12, D16) A valve is installed in the oil filter bracket which opens or closes the oil supply for piston cooling, depending on oil pressure. If the oil pressure is below 240 kPa (35 PSI), the valve closes the oil supply for piston cooling. The piston cooling pressure is monitored by a pressure monitor. The output signal from the pressure monitor can only have two distinct positions, on/off, in the same way as a relay output. The monitor is supplied with current from the EMS2. A preset pressure limit of 150 kPa (22 PSI) determines when the monitor switches on. The monitor opens if the pressure exceeds this value. At idle, the monitor can be closed without a fault code being set.

Sensor, piston cooling (D11) The sensor measures piston cooling pressure and is located in front of the engine. The sensor is an active sensor, i.e. the sensor requires a supply voltage of +5 Volt. The sensor provides an output signal whose voltage is proportional to the pressure that the sensor measures.

Sensor, fuel pressure The sensor measures fuel pressure and is located on the fuel filter bracket. The sensor is an active sensor, i.e. the sensor requires a supply voltage of +5 Volt. The sensor provides an output signal whose voltage is proportional to the pressure that the sensor measures.

44

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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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30-0 General

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

46

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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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30-0 General

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 ed 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.

48

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30-0 General

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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30-0 General

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

SDU Control

Marine Control Unit (MCU)

P0011560 P0017109

IMPORTANT!

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

50

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

P0017121

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

P0017122

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.

52

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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: T. P. F. I. A.

P0017140

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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)

53

30-0 General

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 istration, page 9.

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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30-0 General

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 istration, page 9.

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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30-0 General

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.

56

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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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30-0 General

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”.

C

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:

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

D

Air inlet pressure / intake manifold temperature

• Air inlet pressure / intake manifold temperature

E

Crankcase pressure

• Fuel pressure

F

Coolant temperature

• Fuel alarm, ”water in fuel”

G Diagnostics H

Camshaft position

I

Fuel alarm, water in fuel

J

Fuel pressure

K

Coolant level/oil level

L


M Checking the wastegate control (D12) N

Fuel volume

• 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 pins to come into 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 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:

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

•

•

Check that there is good mechanical 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 ”ing 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. 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.

62

•

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

9 869 999

7

6 5 4 3 2 1

10 9

8

17 24

31 38

45 51

56 55

54 53

52

50

49 48

47 46

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.

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

64

1

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

2

Turn on the main switch.

3

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

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Checking the charging system

Fault tracing the charging system

Special Tools: 9812519.

Battery

Generally about alternators: 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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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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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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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 s and instruments are activated. All relays connected to the starter switch and start / stop s 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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Changing control unit Programming the control unit IMPORTANT! The chassis number or engine serial number must be available to allow the software to be ed. Action: 1 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 ” software”. Choose the control units to be re-programmed and click the ”” button. The software for the selected control units is now ed to the PDA (Personal Digital Assistant). 5 Take a look under ”Settings”, ”Software information” in Vodia to check that the software has been ed. 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. 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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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 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


Voltage below normal or shorted to lower voltage

5


Current below normal or open circuit.

6


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

72

Help

2

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

3

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

4

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

5

Open circuit in unit injector circuit.

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

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 . 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 •


•

An orange lamp flashes in the alarm display.

Symptom:

None

Preconditions:

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


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 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:

Faulty sensor/Fault in sensor circuit

Fault indication:

•


•


Symptom:

None

Preconditions:



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

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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. •


•


Symptom:

None

Preconditions:

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


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.


Faulty sensor/Fault in sensor circuit. •


•


Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•

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

•


1 Check cables and connectors between the sensor and engine control unit. 2 Check pressure in socket 18 in engine connector B. 3 Check sensor.

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



•


Symptom:

None

Preconditions:



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 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. •


•


Symptom:

None

Preconditions:

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


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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30-2 Fault Tracing

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

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

Water in Fuel. •


•

Water-in-fuel warning flashes in the alarm .

Symptom:

None

Preconditions:

Water in Fuel


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.


Faulty sensor/Faulty switch circuit •


•


Symptom:

None

Preconditions:

Faulty sensor/Faulty switch circuit.



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 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


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

Y

R /BL

R /BL 4(+)

10

R /BL 5(+)

8

b

P0007195

SB Y

(D13)

(D11)

A

2

B C

3

EMS2 a


b

Power Module

P0008540

a

Connector B

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

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

Faulty sensor circuit

Fault indication:

Yellow alarm status

Fault stored in memory

Yes

Symptom:

None


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


•

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

47700583


81

30-2 Fault Tracing

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:

82

1 Reprogram engine ECU.

47700583


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. •


•

Oil level warning flashes in alarm + 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.




•


Symptom:

None

Preconditions:



•


•

Faulty sensor.

1 Check the cable harness between the sensor and the EMS 2. 2 Level sensor: Check pressure in sockets 3 and 4 in engine connector B. 3 Check the sensor.

D9, D11, D12

47700583

D9CC, D13, D16


83

30-2 Fault Tracing

Circuit description 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.

D9CC

P0010640

D16

b

3 10

GN/SB SB

4

1 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

84

47700583


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

47700583


85

30-2 Fault Tracing

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. •


•

Oil pressure warning flashes in alarm + audible warning.

Symptom:

Engine is derated.

Preconditions:

Oil pressure too low.


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.




•


Symptom:

None

Preconditions:



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

Possible reason:

Suitable action:

•


•

Faulty sensor.

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

86

47700583


30-2 Fault Tracing


Faulty sensor/Fault in sensor circuit.

Fault indication:

•


•


Symptom:

None

Preconditions:



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

Possible reason:

Suitable action:

•


•


•


•


•

Faulty sensor.

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

GR / OR

P2

EMS2 b 11

BL / OR

P0007206

a

Connector A

b

Connector B

c

Oil pressure/temperature sensor

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

D13 b

a 17 R SB 18 11

BL / OR

4

a

(+)7 (-)11

1

P2

EMS2

R SB

EMS2 b

4

c

1

P2

11 BL / OR P0017176

P0017175

P0017175

a

Oil pressure sensor

b

Connector B

47700583


a

Connector A

b

Connector B

c

Oil pressure sensor

87

30-2 Fault Tracing

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

88

47700583


30-2 Fault Tracing

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. •


•


Symptom:

Engine is derated

Preconditions:

Intake manifold temperature is too high


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:



•


Symptom:

None

Preconditions:

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


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

Possible reason:

Suitable action:

•


•

Faulty sensor


47700583


89

30-2 Fault Tracing




•


Symptom:

None

Preconditions:



Voltage on engine control unit pin A47 exceeds 4.95 volts.

Possible reason:

Suitable action:

•


•


•

Faulty sensor

1 Check cables and connectors between the sensor and engine control unit. 2 Check pressure in socket 47 in engine connector A. 3 Check the sensor.

D9, D12

90

D11, D13, D16

47700583


30-2 Fault Tracing

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


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

47700583


91

30-2 Fault Tracing

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. •


•


Symptom:

Engine is derated.

Preconditions:

Air inlet pressure too high.


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. NOTICE! Only applicable to D12.




•


Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•

Short circuit between sensor signal cable and sensor supply cable or battery voltage

•


•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit. 2 Check pressure in socket 11 in engine connector B. 3 Check the sensor.

92

47700583


30-2 Fault Tracing




•


Symptom:

None

Preconditions:

Current below normal or open circuit



Possible reason:

Suitable action:

•


•


•

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

D9. D12

47700583

D11, D13, D16


93

30-2 Fault Tracing

D9, D12

a

ConnectorA Color: Black

b


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


c

t

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

94

47700583


30-2 Fault Tracing

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 •


•

The warning symbol in the alarm flashes red. The coolant temperature symbol in the alarm flashes red. Audible warning.

Symptom:

Engine is derated.

Preconditions:

Coolant temperature too high


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.

47700583


95

30-2 Fault Tracing




•

Orange lamp flashing in alarm .

Symptom:

None

Preconditions:

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



Possible reason:

Suitable action:

•


•

Faulty sensor.





•

Orange lamp flashing in alarm .

Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•


•


•

Faulty sensor.


D9, D12, D16

D11, D13

p0004941

96

47700583


30-2 Fault Tracing

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

47700583


97

30-2 Fault Tracing

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 •


•

Coolant indicator lamp flashing in alarm .

Symptom:

None


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:



Excessive voltage on engine control unit pin B23.

Possible reason:

Short circuit to battery voltage on pin B23.

Suitable action:

98

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

47700583


30-2 Fault Tracing

b


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.

P0007222

a

Coolant level monitor

b


The level monitor comprises two parts, the actual monitor and a magnetic float built into the expansion tank. The monitor senses the position of the magnetic float. When coolant level drops, the float acts on the level monitor whose resistance drops to zero whereupon a closed circuit is formed.

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

47700583


99

30-2 Fault Tracing

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 •


•


Symptom:

Engine is derated and limited to 1200 rpm.

Preconditions:

Crankcase pressure too high


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.




•


Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•


•


•

Faulty sensor.


100

47700583


30-2 Fault Tracing




•


Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•


•


•


•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit. 2 Check pressure in sockets 17 and 28 in engine connector B. 3 Check sensor.

47700583


101

30-2 Fault Tracing

b


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

102

47700583


30-2 Fault Tracing

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. •


•


•

Battery indicator lamp flashing in alarm .

Symptom:

None

Preconditions:

Data valid but below operational range.


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.

47700583


103

30-2 Fault Tracing

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 .

Symptom:

None


Timeout in communication on the secondary bus J1587.


•

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.

104

47700583


30-2 Fault Tracing

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 •


•


Symptom:

None

Preconditions:

Exhaust temperature too high


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.




•


Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•


•

Faulty sensor.

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

47700583


105

30-2 Fault Tracing


Faulty sensor/Fault in sensor circuit

Fault indication:

•


•


Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•


•

Open circuit in sensor negative cable.

•

Faulty sensor.

1 Check the cable harness between the sensor and the EMS 2. 2 Check 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, page 186 Checking negative cable, exhaust temperature sensor, page 186 Checking exhaust temperature sensor, page 187

106

47700583


30-2 Fault Tracing

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


Engine oil temperature too high •


•


Symptom:

Engine is derated.

Preconditions:

Engine oil temperature too high


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 by valve for the oil cooler. For more detailed instructions, refer to Workshop manual group 22, Lubrication system.




•


Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•


•

Faulty sensor

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

47700583


107

30-2 Fault Tracing




•


Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•


•


•

Open circuit in sensor negative cable

•

Faulty sensor.

1 Check cables and connectors between the sensor and engine control unit. 2 Check pressure in socket 11, engine connector A, and socket 11 in engine connector B. 3 Check the sensor.

108

47700583


30-2 Fault Tracing

a (+)7 (-)11 31

R SB GR / OR

c 4

1 3

P2

EMS2 b 11

BL / OR

P0007206

a

ConnectorA Color: Black

b


c

Oil temperature sensor

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

47700583


109

30-2 Fault Tracing

MID 128, PID 175 Engine oil temperature D13, D16


Engine oil temperature too high •


•


Symptom:

Engine is derated.

Preconditions:

Engine oil temperature too high


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 by valve for the oil cooler. For more detailed instructions, refer to Workshop manual group 22, Lubrication system.




•


Symptom:

None

Preconditions:




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.

110

47700583


30-2 Fault Tracing




•


Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•

Open circuit in the oil temperature signal cable.

•


•

Faulty sensor.

1 Check the cable harness between the sensor and the EMS 2. 2 Check pressure in socket 10, engine connector B, and socket 31 in engine connector A. 3 Check the sensor.

47700583


111

30-2 Fault Tracing

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

112

47700583


30-2 Fault Tracing

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. •


•


Symptom:

None

Preconditions:

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


The engine is overspeeding.

Suitable action:

47700583

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


113

30-2 Fault Tracing

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. •


•


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.


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 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, page 194 Checking the pre-start relay, page 194

114

47700583


30-2 Fault Tracing

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:

•


•


Symptom:

Engine stops or cannot be started.

Preconditions:




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. •


•


Symptom:


Preconditions:

Stop input is activated.


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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115

30-2 Fault Tracing

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

Measurements Checking the external stop voltage potential, page 195

116

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30-2 Fault Tracing

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. •


•


Symptom:

Engine is derated.


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 istration, page 9 to see at what rpm a piston cooling pressure should be expected.


Defective sensor/Defect in sensor circuit •


•


Symptom:

Engine is derated.



Possible reason:

Suitable action:

•


•


•

Faulty sensor.


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117

30-2 Fault Tracing


Defective sensor/Defect in sensor circuit •


•


Symptom:

Engine is derated.


Engine control unit pin A23 voltage lower than 0.30 volts.

Possible reason:

Suitable action:

•


•


•


•

Faulty sensor.


Circuit description 23

GR/R

(+)7

R

(-)11

SB

EMS2 P0008475

a

118


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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30-2 Fault Tracing

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)*

kPa

P0007192

NOTICE! * At normal atmospheric pressure.

V: Output voltage kPa: Piston cooling pressure

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

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119

30-2 Fault Tracing

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


Piston cooling pressure is too low. •


•


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 istration, page 9 to see what rpm a piston cooling pressure should be expected.

SB

a 2

10 SB

14 GR / R

EMS P0007245

a

Piston cooling pressure switch

P1

Circuit description There is a valve in the oil filter bracket that opens and closes piston cooling oil supply depending on oil pressure. If oil pressure is below 240 kPa (D12) or 300 kPa (D16) the valve closes piston cooling oil supply. Piston cooling pressure is overseen by a pressure monitor. The monitor output signal – engine control unit pin 1 – can only have one of two distinct potentials, high or low. The monitor is supplied with power by engine control unit pin 10. A specified pressure 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, page 175 Checking power supply cable, piston cooling pressure sensor, page 176

120

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30-2 Fault Tracing

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

Communication fault •


•


Symptom:

None


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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30-2 Fault Tracing

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


Yes

Symptom:

Engine is derated.

Suitable action: Logging parameter:

122

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

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30-2 Fault Tracing

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

Communication failure •


•


Symptom:

Engine goes to idle.


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.

•


•

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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30-2 Fault Tracing

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


Seawater pressure too low •


•


Symptom:


Preconditions:

Seawater pressure too low


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.


Defective sensor/Defect in sensor circuit. •


•


Symptom:

None

Preconditions:




Possible reason:

Suitable action:

•


•


•

Faulty sensor.

1 Check the cable harness between the sensor and the EMS 2. 2 Check pressure in socket 11 in engine connector A. 3 Check the sensor.

124

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30-2 Fault Tracing


Defective sensor/Defect in sensor circuit.

Fault indication:

•


•


Symptom:

None

Preconditions:

Abnormally low current or open circuit.



Possible reason:

Suitable action:

•


•


•


•

Faulty sensor.

1 Check the cable harness between the sensor and the EMS 2. 2 Check pressure in sockets 7 and 19 in engine connector A. 3 Check the sensor.

a

Circuit description (-) 11

SB

b

(+ ) 7

1 4 R

P2

19

GR P0007246

a

Connector A

b

Seawater pressure sensor

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

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30-2 Fault Tracing

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. •


•


•


•

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.


126

•

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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30-2 Fault Tracing

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:



•


•


•



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.


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



•


•


•



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 pressure in all sockets to unit injectors in engine connector A.

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30-2 Fault Tracing

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



•


Symptom:


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:



•


Symptom:


Preconditions:

NOTICE! Identify the cylinder by using the SID number in the 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 pressure in all sockets to unit injectors in engine connector A. 3 Check the cable connection to the injector.

128

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30-2 Fault Tracing

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 b

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

1 2 3

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

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, page 167 Checking the injector coils, page 168

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129

30-2 Fault Tracing

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


Yes

Symptom:

None


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 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 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.



Fault indication:

Yellow alarm status


Yes

Symptom:

The engine start time will increase. Starting engine by using flywheel sensor.


No cam signal.


•

Open circuit or short circuited sensor cables.

•

Faulty sensor.


130

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30-2 Fault Tracing

FMI 8 – Abnormal frequency, pulse width or period Fault code explanation:


Fault indication:

Yellow alarm status


Yes

Symptom:

The engine start time will increase. Starting engine by using flywheel sensor.


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

D9, D12, D16

D11, D13

P0008694

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131

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)

132

Checking camshaft sensor, page 163

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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:


Fault indication:

Yellow alarm status


Yes

Symptom:


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 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 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



Fault indication:

Yellow alarm status


Yes

Symptom:

Conditions for fault code: Possible reason: Suitable action:

•


•


•


No crank signal. •

Open circuit or short circuited sensor cables.

•

Faulty sensor.


134

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30-2 Fault Tracing

FMI 8 – Abnormal frequency, pulse width or period Fault code explanation:


Fault indication:

Yellow alarm status


Yes

Symptom:


Possible reason:

Suitable action:

•


•


•


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

D9, D12, D16

D11, D13

P0008694

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135

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, page 160

136

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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. •


•


Symptom:


Preconditions:



Excessive voltage on engine control unit pin B 38.


•

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.


Fault in wastegate valve or fault in circuit. •


•


Symptom:


Preconditions:



Voltage too low on engine control unit pin B 38.


•

Short circuited control valve signal to battery negative.

•


1 Check cables and connectors between the control unit and the control valve. 2 Check the wastegate valve.

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137

30-2 Fault Tracing


Fault in wastegate valve or fault in circuit.

Fault indication:

•


•


Symptom:


Preconditions:

Abnormally low current or open circuit.


Wrong voltage on engine control unit pin B 38.


•

Open circuit in control valve signal.

•


1 Check cables and connectors between the control unit and the control valve. 2 Check 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 es 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

138

47700583


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 es through the exhaust turbine. Oil pressure is used to control the amount that the wastegate opens. The wastegate valve is controlled by the EMS. The EMS uses a pulse width modulated signal to control the wastegate valve. P0010641

P0010639

Measurements Checking the wastegate valve, page 159

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139

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:


Symptom:

The engine gives less power, which results in less performance during acceleration and when heavily loaded.


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:


Fault indication:


Symptom:



The voltage at EECU pin B 2 is lower than normal.


•

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



Fault indication:


Symptom:



Incorrect voltage in the engine control unit, pin B 2.


•

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

140

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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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141

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. •


•

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

Symptom:

None



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.


Fault in sensor supply circuit. •


•

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

Symptom:

None



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.

142

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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 •


•


Symptom:

None


Software checksum error

Possible reason:

Failed

Suitable action:

1 Try to reload the software. 2 Try another EECU.

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143

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. •


•


Symptom:

None


Internal fault in engine control unit

Suitable action:

144

1 Change the engine ECU.

47700583


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:

•


•


Symptom:

None


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:


Fault indication:

•


•


Symptom:

None


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

b

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

P0007123

a

PCU connector X3 Color: Pink

b

Engine connector “BUS INTERFACE”

47700583

A B C D H F G E


H Ignition signal

145

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


Yes

Symptom:

At poor sea water flow the exhaust manifold water temperature rises.


Exhaust manifold water temperature exceeds the set value of the engine protection parameter. Refer to istration, page 9.

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


Yes

Symptom:

None


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.

146

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30-2 Fault Tracing

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


Fault indication:

Yellow alarm status


Yes

Symptom:

None


Voltage on pin 43 on engine ECU is too low.


•

Short circuited sensor signal cable to battery negative.

•

Faulty sensor




Fault indication:

Yellow alarm status


Yes

Symptom:

None


Voltage on pin 43 on engine ECU is too high.

Possible reason:

Suitable action:

•


•

Open circuit in sensor battery negative cable.

•

Faulty 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

47700583


Engine ECU B18 B43

Signal type batTemp input

147

30-2 Fault Tracing

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


Fault indication:

•


•


Symptom:

None


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 in power supply to data bus

•


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 pressure in sockets 51 and 55 in engine connector B.

Circuit description A B C D E F G H

a

P0007123

a

PCU connector X3 Color: Pink

b

Engine connector “BUS INTERFACE”

148

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


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

Symptom:

None


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.


•

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.

47700583


149

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

Symptom:

None


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.


•

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.

150

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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:

•


•


Symptom:

None


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


•

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 10 11

a EMS2 A58

2 3

PM

P0017216

a

Power Module

b

8-pole connector

47700583


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.

151

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:


Suitable action:

Open circuit in wires to emergency stop / shutdown relay / EMS2 during start up of power module. •


•


•

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 •


•


Symptom:


Preconditions:

Faulty supply voltage to the engine control unit


Too high current output


•

Short circuit in the system.

•

Too high load

1 Check the cable harness from the power module for short circuit. 2 Reduce load.

152

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30-2 Fault Tracing

(D13) BL/R 5

2 c

1 2

3 4 b

57 60 EMS2 (B)

Circuit description

BL/R BL/R a 13 12

PM

P0017218

a

Power Module

b

Emergency Stop

c

Shutdown relay (only D13)

47700583



153

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 •


•


Symptom:

None

Preconditions:

Faulty supply voltage to the engine control unit


Excessive power in the 24 V supply from the power module. - Water monitor, fuel filter - ”Easy Link” - External stop


•

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

154


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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

47700583


Measurement points

Nominal value

4 - Battery negative

R≈0Ω

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

155

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)

156

47700583


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

47700583


Measurement points

Nominal value

4 - Battery negative*

R≈0Ω


157

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


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.

158

Measurement points

Nominal value

2-4

U ≈ 0,5 V

47700583


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

47700583


159

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.

160

Measurement points

Nominal value

Red/Blue conductor Black conductor

U ≈ Battery voltage

47700583


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.

47700583


Measurement points

Nominal value

Yellow conductor - Black conductor

U ≈ Battery voltage x 0,8

161

30-2 Fault Tracing

Checking the water in fuel switch, fuel filter 2 1

D9, D12, D16

+24V

3

+24V

H2 O 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 pins into a dish of water. The multimeter must show 23-24 V when there is water between the 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.

162

Measurement points

Nominal value

Monitor dipped in water.

R≈0Ω

Monitor dipped in fuel.

R≈∞Ω

47700583


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). V

1

2

3

4

5

5

7 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.

5

75

1

2

3

4

8856

885 675

1

2

P0008931

47700583


163

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


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


R≈0Ω


164

47700583


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

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 (-).

Oil

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.

47700583


165

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

166

47700583


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. On 4 pin injectors the code comprises 9 characters located on the injector's electrical connector below the SN number.

P0001354

2 pin injector

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".

47700583


167

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, page 61. 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


Open circuit


Open circuit


Open circuit


Open circuit


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.

168

47700583


30-2 Fault Tracing

D11

47700583


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

169

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


R≈0Ω

D11, D16


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.

170

47700583


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))

47700583


171

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


R ≈ 80 - 120 kΩ

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

172

47700583


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

47700583


173

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


R ≈ 80 - 120 kΩ

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

174

47700583


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.

47700583


Measurement points

Nominal value


R≈0Ω

175

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


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


R≈0Ω

P0007186

176

47700583


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.

47700583


Measurement points

Nominal value

2–4

U ≈ 0,5 V

177

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


R≈0Ω

D11, D16


R≈0Ω


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.

178

47700583


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*


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.

47700583


Measurement points

Nominal value

D9, D12

1-4

U≈5V

D11, D16

1-3

U≈5V

179

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


R≈0Ω


180

47700583


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.

47700583


181

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.

182

Measurement points

Nominal value

1-2

Battery voltage x 0.8

47700583


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


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.

47700583


Measurement points

Nominal value

Blue conductor - Black conductor

R≈0Ω (Coolant level too low)

183

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 P0007186

184

Measurement points

Nominal value


R≈0Ω


47700583


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


R ≈ 80 - 120 kΩ


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*


47700583


185

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.

186

Measurement points

Nominal value


R≈0Ω

47700583


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 pins. The resistance must correspond to the values in the table.

°C Ω

47700583


Exhaust Temperature Resistance

187

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 P0007186

188

Measurement points

Nominal value


R≈0Ω


47700583


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.

47700583


Measurement points

Nominal value

3-4

U ≈ 0.5 - 4.5 V (depending on the temperature)

189

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

190

Resistance Engine Oil Temperature

3-4

R ≈ 4981Ω +/- 503Ω (at 0° C (32° F))

3-4

R ≈ 1900Ω +/- 163Ω (at 20° C (68° F))

3-4

R ≈ 809Ω +/- 59Ω (at 40° C (104° F))

3-4

R ≈ 378Ω +/- 24Ω (at 60° C (140° F))

3-4

R ≈ 191Ω +/- 10Ω (at 80° C (176° F))

3-4

R ≈ 104Ω +/- 5Ω (at 100° C (212° F))

3-4

R ≈ 60Ω +/- 3Ω (at 120° C (248° F))

47700583


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


R≈0Ω


47700583


191

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.

192

Measurement points

Nominal value

3-4

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

47700583


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

Resistance Engine Oil Temperature

47700583


193

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.

194

47700583


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, page 61. 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)

47700583


195

37-0 Wiring Diagrams

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

196

47700583


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.

47700583


197

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 ed 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 1 3 2

3 Cable marking ”SECONDARY” 4 Secondary solenoid valve

P0008762

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

198

47700583


39-0 General

Index MID 128: Engine control unit Caption

PID

PPID SID

PSID FMI

MID 128, PID 20, Extended Range Engine Coolant Pressure, page 74

20

1, 3, 5

MID 128, PID 94 Fuel Delivery Pressure, page 76

94

1, 3, 5, 7

MID 128, PID 97 Water in fuel indicator, page 79

97

0, 3

MID 128, PID 98 Engine oil level, page 83

98

1, 3

MID 128, PID 100 Engine oil pressure, page 86

100

1, 3, 5

MID 128, PID 105 Intake manifold temperature, page 89

105

0, 4, 5

MID 128, PID 106 Air inlet pressure, page 92

106

0, 3, 5

MID 128, PID 110 Engine coolant temperature, page 95

110

0, 4, 5

MID 128, PID 111 Coolant level, page 98

111

1, 3

MID 128, PID 153 Crankcase pressure, page 100

153

0, 3, 5

MID 128, PID 158 ECU battery potential, page 103

158

1

MID 128, PID 163, Transmission range attained, page 104

163

9

MID 128, PID 173 Exhaust gas temperature, page 105

173

0, 4, 5

MID 128, PID 175 Engine oil temperature, page 107 (D9, D11, 175 D12)

0, 4, 5

Engine Oil Temperature (D16)

175

0, 4, 5

MID 128, PID 190 Engine speed, page 113

190

0

MID 128, PPID 3 Starter Output, page 114

3

3, 4, 5

MID 128, PPID 6 Key off input sensor, page 115

6

4, 11

MID 128, PPID 8 Piston Cooling Oil Pressure, page 117 (D9, D12, D16)

8

1

Piston cooling oil pressure (D11)

8

1, 3, 5

MID 128, PPID 98 Engine sync acknowledge, page 121

98

9

MID 128, PPID 117 Engine protection status, page 122

117

7

MID 128, PPID 132 Throttle Calibrated Position, page 123

132

9

MID 128, PPID 267, Sea water pressure, page 124

267

1, 3, 5

MID 128, SID 1/2/3/4/5/6 Injector # 1-6, page 126

1/2/3/4/5/6

3, 4, 5, 7, 12

MID 128, SID 21 Engine position, page 130

21

2, 3, 8

MID 128, SID 22 Timing sensor, crank, page 133

22

2, 3, 8

MID 128, SID 32, Wastegate output driver, page 137

32

3, 4, 5

MID 128, SID 89 Air Compressor Actuator Circuit, page 140

89

3, 4, 5

MID 128, SID 232 5 V supply, page 142

232

3, 4

MID 128, SID 240 Program memory, page 143

240

2

MID 128, SID 254 Controller 1, page 144

254

3, 12

MID 128, SID 231 SAE J1939 data link, page 145

231

2, 9

MID 128, PSID 112 Exhaust Manifold Water Temperature Sensor #1, page 146

112

0, 3, 4, 5

MID 128, PSID 216 Data Link, MID187, page 148

216

9

47700583


199

39-0 General

MID 158: Power module Caption

PSID

FMI

MID 158, PSID 1, Primary battery circuit, page 149

1

3, 4

MID 158, PSID 2, Secondary battery circuit, page 150

2

3, 4

MID 158, PSID 4, 30 supply fuse, page 151

4

6

MID 158, PSID 5, EMS supply fuse, page 152

5

5, 6

MID 158, PSID 6, Extra supply fuse, page 154

6

6

200

47700583


Index A About this Workshop manual..................................... 2 Adjustment parameters for low-speed or trolling function................................................................... 197 C Checking camshaft sensor..................................... 163 Checking exhaust temperature sensor................... 187 Checking flywheel sensor....................................... 160 Checking negative cable, air inlet pressure sensor 178 Checking negative cable, coolant pressure sensor 155 Checking negative cable, coolant switch................ 183 Checking negative cable, coolant temperature sensor..................................................................... 180 Checking negative cable, crankcase pressure sensor..................................................................... 184 Checking negative cable, exhaust temperature sensor..................................................................... 186 Checking negative cable, fuel pressure sensor...... 157 Checking negative cable, intake manifold temperature sensor................................................ 170 Checking negative cable, oil level switch............... 164 Checking negative cable, oil temperature sensor............................................................. 188, 191 Checking negative cable, piston cooling pressure sensor.............................................. 175, 176 Checking negative cable, seawater pressure sensor..................................................................... 173 Checking negative cable, water switch, fuel filter... 161 Checking power supply cable, oil temperature sensor..................................................................... 189 Checking power supply cable, piston cooling pressure sensor.............................................. 176, 177 Checking propeller rotation.................................... 198 Checking signal cable, air inlet pressure sensor.... 178 Checking signal cable, coolant pressure sensor.... 156 Checking signal cable, coolant temperature sensor 181 Checking signal cable, crankcase pressure sensor 185 Checking signal cable, exhaust temperature sensor..................................................................... 186 Checking signal cable, fuel pressure sensor.......... 158 Checking signal cable, intake manifold temperature sensor................................................ 170 Checking signal cable, oil pressure sensor............ 172 Checking signal cable, oil temperature sensor....... 192 Checking signal cable, seawater pressure sensor. 174 Checking signal cable, water switch, fuel filter....... 161 Checking supply cable, air inlet pressure sensor... 179 Checking supply cable, coolant pressure sensor... 155 Checking supply cable, coolant switch................... 182 Checking supply cable, crankcase pressure sensor..................................................................... 184 Checking supply cable, fuel pressure sensor......... 157 Checking supply cable, oil level switch.................. 164 Checking supply cable, oil pressure sensor........... 172 Checking supply cable, seawater pressure sensor 174 Checking supply cable, water switch, fuel filter...... 160 Checking the air inlet pressure sensor................... 179 Checking the coolant pressure sensor................... 156 Checking the coolant switch................................... 183 47700583


Checking the coolant temperature sensor.............. 182 Checking the crankcase pressure sensor.............. 185 Checking the external stop voltage potential.......... 195 Checking the fuel pressure sensor......................... 158 Checking the injector coils...................................... 168 Checking the intake manifold temperature sensor. 171 Checking the oil level sensor.................................. 166 Checking the oil level switch.................................. 165 Checking the oil pressure sensor........................... 173 Checking the oil temperature sensor.............. 190, 193 Checking the piston cooling pressure sensor......... 177 Checking the pre-start relay................................... 194 Checking the seawater pressure sensor................ 175 Checking the starter motor solenoid....................... 194 Checking the wastegate valve................................ 159 Checking the water in fuel switch, fuel filter........... 162 Component description............................................ 42 Component location................................................. 32 D Design and Function.......................................... 32, 58 E Engine Protection Map............................................... 9 F Fault Codes.............................................................. 74 Fault Tracing............................................................ 74 Function fault............................................................ 72 G General......................................................... 2, 32, 197 I Index....................................................................... 199 Injector trim............................................................. 167 M Measurements........................................................ 155 MID 128, PID 100 Engine oil pressure..................... 86 MID 128, PID 105 Intake manifold temperature....... 89 MID 128, PID 106 Air inlet pressure......................... 92 MID 128, PID 110 Engine coolant temperature........ 95 MID 128, PID 111 Coolant level............................... 98 MID 128, PID 153 Crankcase pressure.................. 100 MID 128, PID 158 ECU battery potential................ 103 MID 128, PID 163, Transmission range attained... 104 MID 128, PID 173 Exhaust gas temperature.......... 105 MID 128, PID 175 Engine oil temperature...... 107, 110 MID 128, PID 190 Engine speed............................ 113 MID 128, PID 20, Extended Range Engine Coolant Pressure...................................................... 74 MID 128, PID 94 Fuel Delivery Pressure................. 76 MID 128, PID 97 Water in fuel indicator................... 79 MID 128, PID 98 Engine oil level.............................. 83 MID 128, PPID 117 Engine protection status......... 122 MID 128, PPID 132 Throttle Calibrated Position.... 123 MID 128, PPID 267, Sea water pressure............... 124 MID 128, PPID 3 Starter Output............................. 114 MID 128, PPID 6 Key off input sensor.................... 115 MID 128, PPID 8 Piston Cooling Oil Pressure 117, 120 MID 128, PPID 98 Engine sync acknowledge........ 121

201

MID 128, PSID 112 Exhaust Manifold Water Temperature Sensor #1......................................... 146 MID 128, PSID 216 Data Link, MID187.................. 148 MID 128, SID 1/2/3/4/5/6 Injector # 1-6.................. 126 MID 128, SID 21 Engine position........................... 130 MID 128, SID 211 Sensor Supply Voltage #2 (+5 V DC)................................................................. 81 MID 128, SID 22 Timing sensor, crank.................. 133 MID 128, SID 231 SAE J1939 data link................. 145 MID 128, SID 232 5 V supply................................. 142 MID 128, SID 240 Program memory...................... 143 MID 128, SID 253 Calibration memory EEPROM ... 82 MID 128, SID 254 Controller 1............................... 144 MID 128, SID 32, Wastegate output driver............. 137 MID 128, SID 89 Air Compressor Actuator Circuit. 140 MID 158, PSID 1, Primary battery circuit................ 149 MID 158, PSID 2, Secondary battery circuit........... 150 MID 158, PSID 4, 30 supply fuse........................... 151 MID 158, PSID 5, EMS supply fuse....................... 152 MID 158, PSID 6, Extra supply fuse....................... 154 R Repair Instructions................................................... 61 Repair instructions...................................................... 3 S Safety Information.................................................... 26 Safety Instructions.................................................... 26 Special Service Tools............................................... 30 Specifications, Electrical............................................. 5 Switches and Senders................................................ 5 W Wiring Diagrams..................................................... 196

202

References to Service Bulletins Group No.

Date

Refers to

............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. ............................................................................................................................................................................. .............................................................................................................................................................................

203

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AB Volvo Penta Service Communication Dept. CB22000 SE-405 08 Gothenburg Sweden

47700583 English

08--2017

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