Workshop Manual I

Group 30 Electrical system 5(0)

SCR
Content

General Information
00-0 General ................................................................................................ 2

Specifications
03-3 Specifications, Electrical ................................................................. 11

Safety and Other Instructions

05-1 Safety Instructions ........................................................................... 13

Special tools
08-2 Special Service Tools ....................................................................... 17

General, Complete Vehicle Software

30-0 General .............................................................................................. 19
Design and Function ................................................................................ 19
30-2 Fault Tracing ..................................................................................... 48
Fault Codes ............................................................................................... 48
Measurements ......................................................................................... 111
30-3 Bi-Fuel Engines ............................................................................... 125
Technical Data ......................................................................................... 125
Fault Codes ............................................................................................. 126
Measurements ......................................................................................... 135

Cables and fuses

37-0 Wiring Diagrams ............................................................................. 138

Miscellaneous
39-0 General ............................................................................................ 157
Alphabetical index .................................................................................. 159
References to Service Bulletins ............................................................ 161
00-0 General
Concerned engines
This Workshop Manual concerns the following engine models:

• TAD1360VE • TAD1660VE • TAD762VE

• TAD1361VE • TAD1661VE • TAD763VE
• TAD1362VE • TAD1662VE • TAD764VE
• TAD1363VE • TAD560VE • TAD765VE
• TAD1364VE • TAD561VE • TWD1663GE
• TAD1365VE • TAD761VE • TWG1663GE

2 47702556 02-2012
 00-0 General

About this Workshop manual

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

47702556 02-2012 3
00-0 General

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

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 inter-
vals may otherwise result.

4 47702556 02-2012
 00-0 General

Lock nuts Anaerobic agents.

These agents cure (harden) in the absence of air.
Removed locknuts may not be re-used; they must These preparations are used when two solid com-
be replaced by new ones, as locking properties are ponents, e.g. two cast components, are fitted
impaired or lost with re-use. together without a gasket. Common uses are also
In the case of lock nuts with plastic inserts the tight- to lock and seal plugs, stud threads, taps, oil pres-
ening torque indicated must be reduced if the nut sure monitors etc.
has the same nut height as a standard, all-metal
hexagonal nut. Hardened anaerobic preparations are glassy and
Reduce the torque by 25% for bolt sizes of 8 mm or for this reason, the preparations are colored to
larger. make them visible. Hardened anaerobic prepara-
In the case of lock nuts with plastic inserts with a tions are highly resistant to solvents, and old com-
high nut-height (where the all-metal thread is as pound cannot be removed. On re-assembly, it is
high as a standard hexagonal nut), the indicated important to carefully degrease and wipe dry com-
torque applies. ponents first, before applying new sealant in
accordance with the instructions.
Strength classes
Safety regulations for fluorocarbon
Nuts and bolts are subdivided into different strength
classes. The classification is shown by a marking rubber
on the bolt head. Markings of a higher number indi- Fluorocarbon rubber is a common material in seal-
cate stronger material. For example, a bolt marked ing rings for shafts, and in O-rings, for example.
10-9 is stronger than one marked 8-8.
When fluorocarbon rubber is exposed to high tem-
For this reason, it is important that when bolts are peratures (above 300°C/572°F), hydrofluoric acid
removed they are returned to their original locations can form. This is highly corrosive. Contact with the
on re-assembly. When replacing bolts check the skin can result in severe chemical burns. Splashes
applicable Spare parts catalogue to ensure the in your eyes can result in chemical wounds. If you
correct bolt is used. breathe in the fumes, your lungs can be perma-
nently damaged.
Sealing compounds etc.
To ensure service work is correctly carried out it is WARNING!
important that the correct type of sealants and lock- Seals must never be cut with a torch, or be burnt
ing fluids are used on joints where such are afterwards in an uncontrolled manner. Risk for
required. poisonous gases.
In each service manual section concerned, the seal-
ants used in product manufacture are indicated. WARNING!
The same sealants, or sealants with equivalent Always use chloroprene rubber gloves (gloves for
properties, must be used for maintenance work. chemicals handling) and goggles. Handle the
removed seal in the same way as corrosive acid. All
Make sure that mating surfaces are dry and free residue, including ash, can be highly corrosive.
from oil, grease, paint and anti-corrosion agent Never use compressed air to blow clean.
before applying sealant or locking fluid. Always fol-
Put the remains in a plastic container, seal it and
low the manufacturer's instructions regarding appli-
apply a warning label. Wash the gloves under
cable temperatures, hardening times and such.
running water before removing them.
Two basic types of compound are used:
The following seals are most probably made from
RTV preparations (Room Temperature Vulcaniz- fluorocarbon rubber:
ing).
Seal rings for the crankshaft, camshaft, idler shafts.
Used most often together with gaskets, e.g. sealing
gasket joints, or are brushed on gaskets. RTV seal- O-rings, regardless of where they are installed. O-
ants are completely visible when the part has been rings for cylinder liner sealing are almost always
removed. Old RTV sealant must be removed before made of fluorocarbon rubber.
the component is sealed again. Use denatured
alcohol. Please note that seals which have not been
exposed to high temperature can be handled
normally.

47702556 02-2012 5
00-0 General

AdBlue WARNING!
In the case of any contact with eyes or skin the
Keep Clean affected area must be thoroughly rinsed with luke-
warm water. If you breathe in any fumes, make sure
you breathe fresh air.

CAUTION!
Gloves must be changed. Take off contaminated
clothes.

IMPORTANT!
P0011697
Tools that have been in contact with AdBlue must be
cleaned.

p0013225

Handling of AdBlue by service work

When handling AdBlue, it is very important that all
electrical connectors are protected well, if not there is
a risk that the Adblue will cause oxide that is not pos-
sible to clean. Water and compressed air will not help
because Adblue oxide the metall itself. If a connector
have been in contact with Adblue, it must be
changed immediately to prevent the AdBlue from
"creeping" futher into the cable harness, wich happen
with a speed of 0,6m/h.

NOTICE! Before disconnecting AdBlue hoses,

AdBlue filter etc., always carry out a engine key-off or
run Vodia test "forced blowout" to drain the Adblue
back to the tank.

NOTICE! Always put the connection plugs in the

AdBluehoses, pump unit, dosing valve and tank
when disconnecting. This for protecting the system
against dirt and spill that causes crystallization of the
AdBlue.
p0013232

Protect the electric connections

6 47702556 02-2012
 00-0 General

SCR Warnings and Inducement

USA version

DEF Tank Level

Triggers DCU Display Level Indicator Amber Inducement
Message Warning
Lamp
> 23% Tank None None None None
Level
< 8–23% DEF/AdBlue None None
Tank Level level low

P0013960

< 8% Tank DEF/AdBlue None Ramped torque reduc-

Level level empty tion 1% per minute to
(alternately) full inducement.
Engine derate Full inducement is 0%
available torque > 900
rpm.

P0010777

< 8% Tank DEF/AdBlue None Full inducement from

Level after level empty start, 0% available tor-
restart (alternately) que > 900 rpm.
Severe induce-
ment

P0010777

SCR Tampering
Possible reason:
1. Disconnected DEF tank level sensor 4. Disconnected DEF pump
2. Blocked DEF line or dosing unit 5. Disconnected SCR wiring harness
3. Disconnected DEF dosing unit 6. Disconnected NOx Sensor

47702556 02-2012 7
00-0 General

Triggers DCU Display Message Amber Warning Inducement

Lamp
No Tampering None None None
Tampering confirmed AdBlue/DEF System Warn-
ing
P0002361

Tampering detected AdBlue/DEF System Warn- Ramped torque reduction 1% per

ing (alternately) minute to full inducement.
Engine derate P0002361 Full inducement is 0% available
torque > 900 rpm.
Tampering initial AdBlue/DEF System Warn- Full inducement from start, 0%
detected after restart ing (alternately) available torque > 900 rpm.
Severe inducement P0002361

DEF Quality
Triggers DCU Display Message Amber Warning Inducement
Lamp
Good Quality None None None
Poor quality initial AdBlue/DEF System Warning None
detected
P0002361

Poor quality initial AdBlue/DEF System Warning Ramped torque reduction 1%

detected (alternately) per minute to full inducement.
Engine derate P0002361 Full inducement is 0% available
torque > 900 rpm.
Poor DEF Quality initial AdBlue/DEF System Warning Full inducement from start, 0%
detected after restart (alternately) available torque > 900 rpm.
Severe inducement P0002361

Temporary exit from AdBlue/DEF System Warning See below, “Exit conditions for
severe inducement (alternately) DEF Quality severe inducement”
Temporary Override of P0002361
Inducement

Exit conditions for DEF Quality severe inducement:

First restart With service tool clearing
Allow time to run the quality check function. If poor Allow time to run the quality check function. If poor
DEF quality is detected during the first monitoring DEF quality is detected during the first monitoring
cycle, then inducement is resumed. cycle, then severe inducement is resumed. Induce-
Service tool is required to exit at this point. ment ends when quality fault ceases.

8 47702556 02-2012
 00-0 General

EU version

Adblue tank level

Triggers DCU Display Level Indicator Amber Inducement
Message Warning
Lamp
> 12% Tank None None None None
Level
< 12% Tank DEF/AdBlue level None None
Level low

P0013960

< 0% Tank DEF/AdBlue level None Ramped torque

Level empty (alter- reduction from 0% to
nately) 25% at a rate of 1%
Engine derate per minute.

P0010777

< 0% Tank DEF/AdBlue level None Severe inducement

Level after empty (alter- from start.
restart nately) Torque reduction
Severe induce- 80%.
ment

P0010777

SCR Tampering
Possible reason:
1. Disconnected AdBlue tank level sensor 4. Disconnected AdBlue pump
2. Blocked AdBlue line or dosing unit 5. Disconnected SCR wiring harness
3. Disconnected AdBlue dosing unit 6. Disconnected NOx Sensor

47702556 02-2012 9
00-0 General

Triggers DCU Display Message Amber Warning Inducement

Lamp
No Tampering None None None
Tampering confirmed AdBlue/DEF System Warning

P0002361

Tampering initial detected AdBlue/DEF System Warning Ramped torque reduction

+ 10 hours after restart (alternately) from 0% to 25% at a rate
Engine derate P0002361 of 1% per minute.

Tampering initial detected AdBlue/DEF System Warning 25% torque reduction

+ 20 hours after restart (alternately)
Pre severe inducement P0002361

Tampering initial detected AdBlue/DEF System Warning Severe inducement from

+ 20 hours after restart (alternately) start.
Severe inducement P0002361 Torque reduction 80%.

AdBlue Quality
Triggers DCU Display Message Amber Warning Inducement
Lamp
Good Quality None None None
Poor quality initial detected AdBlue/DEF System Warning None

P0002361

Poor quality initial detected AdBlue/DEF System Warning Ramped torque reduction
+ 10 hours (alternately) from 0% to 25% at a rate of
Engine derate P0002361 1% per minute.

Poor DEF Quality initial AdBlue/DEF System Warning Severe inducement from
detected (alternately) start.
+ 20 hours Pre severe inducement P0002361 Exact torque reduction is
25%.
Poor DEF Quality initial AdBlue/DEF System Warning Severe inducement from
detected (alternately) start.
+ 20 hours after restart Severe inducement P0002361 Torque reduction 80%.

Temporary exit from AdBlue/DEF System Warning See below, “Exit conditions
severe inducement (alternately) for AdBlue Quality severe
Temporary Override of Induce- P0002361 inducement”
ment

Exit conditions for AdBlue Quality severe inducement:

First restart With service tool clearing
Return to 25% torque reduction until proper AdBlue qual- Invoke 25% torque reduction until proper
ity evaluation. If poor AdBlue quality is detected during AdBlue quality evaluation.
the next monitoring cycle then severe inducement will be If poor AdBlue quality is detected during the
active after next restart. next monitoring cycle then severe inducement
After the second restart a Service Tool is required to exit will be active after next restart.
the severe inducement.

10 47702556 02-2012
 03-3 Specifications, Electrical

03-3 Specifications, Electrical

Technical Data
Sensor, NOx
Voltage 24 V
Minimum supply voltage 16 V
Current (start up) 12 A
Current (average supply current) 0,6 A
Connector 4-pin
Working meassuring range NOx 0 – 510 ppm
Preheating sensor temperature 80 °C to 120 °C
Max tightening torque (Sensor tip) 50 ± 10 Nm (36.9 ± 7.4 lbf-ft)

Combination sensor, Humidity / temperature (inlet air)

Connector 4-pin
Voltage 5 V ± 0,25V
Type Analog sensor
Analog output signal 1 (humidity) 0,5 - 4,5V
Analog output signal 2 (temperature) Resistive
Max tightening torque 27 ± 3 Nm (20±2 lbf-ft)
Working temperature range - 40 °C to +100 °C
Working humidity range 0 to 100 % RH

Combination sensor, AdBlue temperature / level

Voltage 5V
Connector 4-pin
Level output signal 1 (level) 0,5 – 4,5 V
Analog output signal 2 (temperature) Resistive
Working temperature range - 40°C to +140°C

Sensor, Exhaust temperature

Voltage 5 V ± 0,25V
Connector 2-pin
Sensor type PT200 (200Ω 0°C)
Max tightening tourque 45 ± 2 Nm (33.2 ±1.5 lbf-ft)

Throttle (Air inlet, SCR engine)

Voltage motor 24 V
Voltage motor (minimum for throttle positioning) 9V
Current motor in normal operation 0,9 A
Voltage Hall H-bridge for throttle position 5V
Type Ratio metric sensor
Analog output signal (position throttle) 0.5–4,5 V (closed-open)
Connector 5-pin
Closing / opening time 120 ms to 150ms (0-40 °C)

47702556 02-2012 11
03-3 Specifications, Electrical

Closing / opening torque > 2 Nm (1.47 lbf-ft)

Minimum valve positioning steps 0.1°

Tank heating valve

Voltage 24 V
Connector 2-pin
Current 2A

Dosage valve (AdBlue injector)

Connector 2-pin
Voltage 24 V
AdBlue working temperature range at dosage inlet -7°C ≤ T ≤ +70°C

Pump unit
Voltage 24 V
Current (+ filter heater) 3,5 A

12 47702556 02-2012
 05-1 Safety Instructions

05-1 Safety Instructions

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

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

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

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

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

CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate personal injury.

IMPORTANT!
Is used to draw your attention to something that may cause minor damage or a minor
malfunction to the product or property.

NOTICE! Is used to draw your attention to important information that will facilitate the
work or operation in progress.

This symbol is used on our products in certain cases and refers to important informa-
tion in the instruction book. Make sure that warning and information symbols on the
engine are clearly visible and legible. Replace symbols which have been damaged or
painted over.

A compilation of safety precautions that must be taken and risks which must be paid attention to is
presented in the following pages.

47702556 02-2012 13
05-1 Safety Instructions

Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply to the engine at the main switch ! engine is hot. Steam or hot coolant can spray
(switches) and lock it (them) in the off position out and system pressure will be lost. Open the
before starting work. Post a warning notice at filler cap slowly, and release the pressure in
the main circuit breaker. 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 car- Hot oil can cause burns. Avoid skin contact
! ried out with the engine stopped. However, ! with hot oil. Ensure that the lubrication system
some work, such as adjustments, will require is not under pressure before any work is
the engine to be running. Approaching an begun. Never start or operate the engine with
engine which is running is a safety risk. Bear the oil filler cap removed, because of the risk
in mind that loose clothing or long hair can of oil ejection.
fasten in rotating parts and cause serious per-
sonal injury.

Be aware of hot surfaces (exhaust pipes, tur- Never start the engine without installing the air
! bos, charge air pipes, starting heaters etc.) ! filter. The rotating compressor turbine in the
and hot fluids in pipes and hoses on an engine turbocharger can cause severe injury. Foreign
that is running or has just stopped. objects entering the intake ducts can also
If work is done adjacent to a running engine, a cause mechanical damage. Install all protec-
careless movement or a dropped tool may in tive covers before the engine is started.
the worst case lead to personal injury.

Ensure that the warning symbols or informa- Only start the engine in a well-ventilated
! tion decals on the product are always clearly ! space. When running in a confined space,
visible. Replace decals which have been dam- exhaust fumes and crankcase gases must be
aged or painted over. led away from the engine bay or workshop
area.

Avoid getting oil on your skin! Protracted or The majority of chemicals e.g. engine and
! repeated exposure to oil can cause skin to ! transmission oils, glycol, gasoline, and diesel
become dry. Irritation, dryness, eczema and oil, together with chemicals for workshop use
other skin problems may then result. From a such as degreasing agents, paints and sol-
health standpoint, used oil is more dangerous vents, are injurious to health. Carefully read
than new. Use protective gloves and avoid oil- the instructions on the product packaging!
soaked clothes and rags. Wash regularly, Always follow a product's safety directions,
especially before eating. Use suitable barrier e.g. use of protective mask, glasses, gloves
creams to counteract drying out of the skin etc. Ensure that other personnel are not
and to aid dirt removal. exposed to substances that are injurious to
health. Ensure good ventilation. Handle used
and leftover chemicals in the prescribed man-
ner.

Stop the engine and turn off the electrical sup- Clutch adjustments must be carried out with
! ply at the main switch(es) before carrying out ! the engine stopped.
work on the electrical system.

14 47702556 02-2012
 05-1 Safety Instructions

Always use protective glasses or goggles Never start the engine with the valve cover
! when carrying out work where a risk of splint- ! removed. There is a risk of personal injury.
ers, grinding sparks, splashes from acid or
other chemicals is present. Your eyes are
extremely sensitive; injury may cause blind-
ness!

Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in ! system.
the inlet manifold. Danger of personal injury. 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 flam- Make sure that oil, fuel-soaked rags, and used
! mable. Do not allow open flames or sparks in ! fuel and oil filters are stored in a safe manner.
their vicinity. Gasoline, some thinners, and Rags soaked in oil can spontaneously ignite
hydrogen gas from batteries are extremely under certain circumstances. Used fuel and oil
flammable and explosive when mixed with air filters are environmentally hazardous waste
in the correct proportions. No Smoking! and must be handed to an approved waste
Ensure that the work area is well ventilated management facility for destruction, as must
and take the necessary safety precautions any used lubrication oil, contaminated fuel,
before welding or grinding work is begun. paint residue, solvents, degreasers and wash
Always ensure that there are fire extinguishers residue.
close at hand in the work area.

Batteries must never be exposed to open Never work alone when removing heavy com-
! flames or electric sparks. Never smoke in the ! ponents, even when using lifting devices such
vicinity of the batteries; they generate hydro- as locking tackle lifts. When using a lifting
gen gas when charged, which is explosive device, two people are usually required to do
when mixed with air. This gas is easily ignited the work - one to take care of the lifting device
and highly explosive. A spark, which can be and the other to ensure that components are
caused by incorrect battery connection, is suf- lifted clear and not damaged during the lifting
ficient to cause a battery to explode and cause operations.
damage.

Do not touch the connections during start

attempts. Sparking hazard! Do not lean over
batteries.

Never transpose the positive (+) and negative The existing lugs on the engine should be
! (-) battery posts when installing batteries. ! used for lifting. Always check that the lifting
Such a transposition can result in serious equipment used is in good condition and has
damage to electrical equipment. Refer to the the load capacity to lift the engine (engine
wiring diagram. weight including gearbox or extra equipment).
Always use protective goggles when charging For safe handling and to avoid damaging com-
and handling the batteries. Battery electrolyte ponents fitted to the top of the engine, the
contains sulfuric acid which is highly corrosive. engine must be lifted with a correctly adjusted
Should the battery electrolyte come into con- lifting boom. All chains or wires must run par-
tact with unprotected skin, wash it off immedi- allel to each other and as perpendicular to the
ately using soap and copious amounts of engine as possible. If other equipment
water. If you get battery acid in your eyes, attached to the engine has altered its center of
flush at once with copious amounts of water gravity, special lifting devices may be needed
and seek medical assistance immediately. to obtain the correct balance for safe handling.
Never perform any work on an engine that is
only suspended from the lifting equipment.

47702556 02-2012 15
05-1 Safety Instructions

The components in the electrical and fuel sys- Exercise extreme caution when leak-detecting
! tems on Volvo Penta products are designed ! on the fuel system and testing the fuel injector
and manufactured to minimize the risk of fire nozzles. Use eye protection. The jet from a
and explosion. The engine must not be run in fuel nozzle has very high pressure and great
areas where there are explosive materials. penetration power. Fuel can force its way
deep into body tissue and cause severe injury.
There is a risk of blood poisoning (septice-
mia).

Only use fuels and lubricating oils recom- Never use a high-pressure washer for clean-
! mended by Volvo Penta. Refer to the Opera- ! ing the engine.
tor's Manual for the product in question. Use Pay attention to the following when using a
of fuels that are of a lower grade may damage high-pressure washer on components other
the engine, the injection pump and the injec- than the actual engine: Never direct the water
tors. On a diesel engine, low grade fuel can jet at seals, rubber hoses or electrical compo-
cause the control rod to bind and the engine to nents.
over-rev, with the risk of engine damage and
personal injury as a result. Low fuel and oil
grades may result in high service, mainte-
nance and repair costs.

Fuel delivery pipes must not be bent or

! straightened under any circumstances. Cracks
may occur. Damaged pipes must be replaced.

16 47702556 02-2012
 08-2 Special Service Tools

08-2 Special Service Tools

Special tools
The following special tools are used when working on
the engine. The tools can be ordered from AB Volvo
Penta by specifying the number indicated.

75
8856

P0008793
5
4
3

2
1

P0006701

885675 Break-out cable 9990014 Break-out cable 9998699 Break-out box

Adapter cable for sensor test. Adapter cable EMS.

VODIA

p0005125 P0013449

p0008375

88820047 VODIA, diagnostic 88890074 Multimeter 88890052 Break-out cable

tool Adapter cable UDS2.
Rugged PDA with SD card.

p0013448 P0013447

88890102 Nipple 88890104 Pump

Pressure test pump nipple Pressure test pump (pump
(pump unit). unit).

47702556 02-2012 17
08-2 Special Service Tools

Other Special Equipment

LVO
52
VO
200
888
21346021 Cable 88820052 VODIA, diagnostic
High speed cable with connec- tool (interface)
tor. Used with docking station VORP docking station. Used
(88820052) on the engine with 88820047 VODIA, diag-
communication connector. nostic tool.

18 47702556 02-2012
 30-0 General

30-0 General

Design and Function

SCR technology

SCR technology (Selective Catalytic Reduction) is

used to meet statutory exhaust requirements as the
stage 3B/tier 4i. Diesel engines with efficient com-
bustion in combination with exhaust gas aftertreat-
ment results in considerably reduced emissions of
nitrogen oxides and particulate matter.

SCR technology is based on treating the exhaust

gases with an additive before they pass through the
catalytic converter. This additive causes nitrogen
oxides to be converted into nitrogen gas and steam,
substance that occure naturally in our environment.
In the following workshop manual we name the addi-
tive AdBlue, but to mention it is also correct to use
DEF (diesel exhaust fluid) which often is used in the
US.

The additive is deionized water solution with 32,5%

urea. This mix must fulfil the ISO-22241-1 standard.
Diesel fuel quality must be according to service bulle-
tin 18-8-8.

IMPORTANT!
Use of AdBlue that does not fulfil the ISO-22241
standard will damage the SCR-system and warranty
will not be valid for any of this damages. Never start
the engine if incorrect AdBlue is filled by misstake.

IMPORTANT!
Use of diesel that does not fulfil the service bulletin
18-8-8 will damage the SCR-system and warranty
will not be valid for any of this damages. Never start
the engine if incorrect diesel is filled by misstake.

47702556 02-2012 19
30-0 General

Glossary for SCR

Abbreviation / word Explanation
AdBlue Deionized water solution with 32,5% urea
Additive AdBlue/DEF (deionized water solution with 32,5% urea)
AHI After-treatment Hydrocarbon Injector
CAN Controller Area Network
CIU Control Interface Unit
DEF Diesel Exhaust Fluid (Deionized water solution with 32,5% urea)
DM Dosing Module (AdBlue injector/Dosing valve)
DU Display Unit
DCU Display Control Unit
EATS Exhaust After Treatment System
EECU Engine Electrical Control Unit
EMS Engine Management System
FMI Fault Mode Identifier
(The same as SID but this is a Volvo-specific component)
MID Message Identifier
(The MID consists of a number which designates the control unit that sent
the fault message)
NOx Nitrogen oxide
N/A Not applicable
PID Parameter Identification description
(consists of a number that designates a parameter (value) to which the fault
code relates)
PPID Proprietary PID
(the same as PID, but this is a Volvo-specific parameter)
PSID Proprietary SID
(the same as PID, but this is a Volvo-specific parameter)
Reagent AdBlue/DEF (deionized water solution with 32,5% urea)
SCR Selective Catalytic Reduction
SID Subsystem Identification description
(the SID consists of a number that designates a component to which the fault
code relates)
SM Supply Module (Pump unit)
SOV Shut Off Valve
UBAT Battery Voltage
UDS2 Urea Dosing System, version MID233
VBAT Battery Voltage

20 47702556 02-2012
 30-0 General

Main Components
SCR and base engine, overview

5
3

10 7
1
8

P0011660 9

1 AdBlue tank
2 Sensor for temp, level and integrated heating
3 Warm-up solenoid valve, (coolant from engine)
4 Pump unit(with integrated control unit UDS2, MID233)
5 Humidity sensor (not used on TAD 56x-TAD 76x)
6 Flexible hose (stainless) (On TAD 56x-TAD 76x also a pre-cat installed after turbo charger)
7 Dosing valve (AdBlue injector)
8 Exhaust temperature sensor
9 SCR catalyst & muffler
10 NOx sensor, exhaust pipe outlet.

The entire SCR system is controlled by the engine control unit (EMS, MID128) which communicates via a sec-
ond control unit (UDS2, MID 233)

47702556 02-2012 21
30-0 General

SCR, overview

1 2 6

7
8 5

P0011661

1 Sensor for temp, level and integrated heating

2 Warm-up solenoid valve, (coolant from engine)
3 SCR muffler with catalytic converter
4 Exhaust inlet pipe
5 Dosing valve (AdBlue injector)
6 Exhaust temperature sensor
7 NOx sensor interface
8 Pump unit (with integrated control unit UDS2, MID233)
9 AdBlue / DEF tank

22 47702556 02-2012
 30-0 General

SCR, function description

1
2
Q
3
t

8
M
4 6
5 p

9 10
t
7
11

13 15
12

t NOx

P0013639
14 16

The picture shows the SCR-systems main components.

1 AdBlue tank 9 Strainer

2 Level sensor, AdBlue tank 10 Direction valve
3 Temperature sensor, AdBlue tank 11 Pipe (with returnflow heaters)
4 Pump, AdBlue 12 Non return valve with restrictor
5 Filter, AdBlue 13 Dosing valve (AdBlue injector)
6 Pressure sensor, AdBlue 14 Exhaust temperature sensor
7 Temperature sensor, AdBlue 15 SCR catalyst & muffler
8 Control unit (UDS2, MID233) 16 NOx-sensor (Only used for OBD, On Board
Diagnostics)

The SCR-system is managed by the EMS (MID128) and the UDS2 (MID233) wich is integrated into the pump
unit.

47702556 02-2012 23
30-0 General

Normal SCR operation and

function
Sequence :
The UDS2 (8) receives a signal from the AdBlue- The exhaust temperature sensor (14) measure the
tank level sensor (2) that the AdBlue-level is above temperature on the exhausts before they enter the
minimum level. catalyst (muffler).

The UDS2 activates the direction valve (10) and The EMS uses the temperature value received from
starts the pump (4), that suck in the AdBlue from the the UDS2 to calculate the temperature of the cata-
tank (1) through a strainer (9) and the direction lyst (muffler). The catalyst (muffler) temperature is
valve (10). The pump is then pressing AdBlue one of the parameters that determine if and which
through the direction valve to the AdBlue-filtrer (5) amount of AdBlue that is injected, the other parame-
and further on to the dosing valve (13) located on ters are engine load, engine speed and humidity/
the inlet pipe to the SCR catalyst (muffler) (15). temp. on air inlet (not used on TAD 56x-76x).

When a number of conditions is fulfilled, e.g. when Since AdBlue is temperature sensitive (freeze temp.
the AdBlue system pressure is high enough, when -11 °C ) the tank is heated through a heating coil
the exhaust temperature is hot enough, etc. the with engine coolant. The hoses and the filter (5) are
EMS (MID128) sends a request to the UDS2 electric heated and are supervised by the AdBlue
(MID233) (8) that opens the dosing valve (13). temperature sensor (7).
AdBlue is then injected into the SCR-catalyst inlet
pipe and the AdBlue surplus is lead via the restrictor The tank temperature sensor (3) is continuously
(12) back to the tank. controlling the AdBlue temperature and give feed-
back to the UDS2 (8) that opens the warm-up sole-
The high temperature on the exhausts decompose noid valve, (coolant from engine) when the AdBlue
the AdBlue and inside the SCR catalyst occur a temperature is lower than 10°C.
chemical reaction that transform the exhausts to
harmless nitrogen and water. The UDS2 (8) close the warm-up solenoid valve,
(coolant from engine) when the AdBlue inside the
The NOx-sensor (16) measure the amount of nitro- tank reaches a temperature above 15°C and the
genoxide (NOx) in the exhausts. If the exhausts heating is terminated.
does not fulfil the emission regulations, a warning
light will be activated and a fault code will be stored If the system discover a fault that affect the AdBlue
in the EMS (MID128). injection, a warning light will be activated and a fault
code will be stored in the control unit.

24 47702556 02-2012
 30-0 General

Normal SCR shutdown

1
2
Q
3
t

8
M

4 6
5 p

9 10
7 t

11

13 15
12

t NOx

P0013643 14 16

When the engine is switched off (key-off), the voltage

to the UDS2 on pin24 goes to 0V which starts the
shutdown sequence (after-run) for the AdBlue sys-
tem. Pump unit, electric heated hoses and injector
are drained of AdBlue to protect system from freez-
ing. This sequence (after run) takes place automati-
cally and takes about 60 seconds depending on the
length of the hoses Also VODIA can be used to drain
the system by running the test "Forced blowout".

Sequence:
Key-off, supply voltage on pin24 to 0V, the AdBlue-
pump stopps and the pressure in the AdBlue-system
falls slowly. The UDS2 (8) close the dosing valve
(13). The UDS2 deactivates the direction valve (10),
that by spring force change the direction towards the
tank (1). The UDS2 starts the pump and drain the
AdBlue system (electric heated hoses, filter, pump
unit) The AdBlue is pumped back to the tank via the
non-return valve (12) that opens. The pressure sen-
sor (6) gives feedback to the UDS2 when the system
is completely drained.

NOTICE! If the SCR-system is not drained properly:

1 Residual pressure in the hoses will spray AdBlue
if a hose is disconnected.
2 The system can freeze and be damaged if the
outside temperature falls below -11°C (12.2°F)

NOTICE! The SCR-system is not drained automati-

cally if battery supply voltage is disconnected, only
with the key-off function.

47702556 02-2012 25
30-0 General

Component description

1. Assembled on base engine

CIU (Control Interface Unit)

The CIU is a "translator" between the CAN bus and
the customer’s own control panel. This unit has two
serial communication links, one fast and one slow.

The fast one is a CAN link that features a bus speed

of 250 Kbit/s. All data regarding instruments, indica-
tor lamps, contacts and potentiometers are controlled
by this bus.

The VODIA diagnosis tool also uses the J1708/

J1587 link to communicate with the system.
P0002060

DCU (Display Control Unit)

DCU is a digital instrument panel that communicates
with the engine control unit via the CAN link. DCU
has several functions, such as:

Engine Control
– Start, stop, speed control, pre-heating etc.
P0002932
Monitoring
– Engine speed, boost pressure, boost temperature,
coolant temperature, oil pressure, oil temperature,
engine hours, battery voltage, instantaneous fuel
consumption, fuel consumption (trip fuel) and AdBlue
tank level.

Diagnostics
– Shows fault codes in text. Lists previous faults.
– Shows Yellow or Red warning symbol when Tam-
pering or Poor DEF Qaulity Detected, if derate active
or not.
– Shows SAE symbol when Low DEF/AdBlue Level

Parameter Setting
– Idling speed, alarm limit for oil temperature/coolant
temperature, droop.
– Preheating for ignition.

Information
– Information about hardware, software and engine
identification.

26 47702556 02-2012
 30-0 General

DU (Display Unit)
The DU is an instrument panel which shows engine
working values graphically on an LCD screen. It con-
sists of a computerised unit for permanent installation
in a control panel.

The display communicates via the CAN link. It is con-

nected to the CAN link between the engine control
unit and the CIU or DCU.

Monitoring
– Engine speed, boost pressure, boost temperature,
coolant temperature, oil pressure, oil temperature,
fuel pressure, engine hours, battery voltage, instanta-
neous fuel consumption and average fuel consump-
tion (trip fuel), AdBlue tank level.

Diagnostics
– Shows active fault codes in plain language.
– Shows Yellow or Red warning symbol when Tam-
pering or Poor DEF Qaulity Detected, if derate active
or not.
– Shows SAE symbol when Low DEF/AdBlue Level

Humidity sensor
(Not used on TAD 56x and 76x VE)

The air inlet humidity and intake temperature are

measured via a combined sensor, located on the
base engines air inlet pipe. It is used for compensate
parameters in the urea dosing strategy.
P0011692

Air throttle
(Not used on TWD/TWG 1663 GE)

The air inlet throttle is controlling the amount of air

that comes into the combustion to affect the exhaust
temperature. The function is used when the engine is
running on lower load etc to keep up the exhaust
temperature which is critical for the SCR system. It is
located on the base engines air inlet pipe. The throt-
tle is mounted with four screws and is using 5-pins
P0010764
on the connector. The main parts are valve, electrical
motor, measuring system for valve position feedback.

47702556 02-2012 27
30-0 General

2. Assembled on SCR system

Dosing valve, AdBlue injector

The AdBlue is dosed into the exhaustgases before
the SCR muffler with the dosing valve. The AdBlue
solution which is not injected, returns to the tank
through the pump unit. The location (angles) of the
dosing valve on the exhaust line or muffler is of great
importance with regards to AdBlue mixing perform-
ance. Heat might be a problem if the injector is posi-
tioned on top of the exhaust pipe. AdBlue crystalliza-
tion on the injector valve tip might be a problem if the
dosing valve is positioned on the bottom of the
exhaust pipe. (see also installation documentation)

p0013248

UDS2 (Urea Dosing System, MID233)

The aftertreatment regent control unit (MID 233,
UDS2) is connected to the engine mounted EMS via
CAN-bus J1939. All faultcodes is sent via the EMS
and therefore the shown source is the EMS
(MID128). The AdBlue amount that is beeing injected
is controlled by the EMS. The UDS2 is integrated in
the pump unit and can not be changed separately. It
is programmed with the Volvo Penta chassis id.

Connections
• CAN
• Diagnosis via engine harness
• Electrical hose heating
1 UDS2 unit • AdBlue tank heating
• Exhaust gas temperature
• Dosing valve actuation
• AdBlue solution level sensor
• AdBlue tank sensor

28 47702556 02-2012
 30-0 General

AdBlue level / Temperature sensor

The level and temperature sensor gives feedback to
the UDS2. The temperature sensor is used for the
2 tank heating (see Solenoid valve (AdBlue tank warm-
up)) and the level sensor is used for level warnings/
derate functions. Volvo Penta AdBlue tank is made of
plastic and available in different sizes. The tank is fit-
ted with ventilation to balance pressure changes, a
magnetic insert for filling interface and a heating cir-
cut with fixing elements. Underneath the tank there is
a drain plug, so the AdBlue can be drained when
cleaning or replacing the level sensor. The suction
pipe is equipped with a filter to prevent particles from
1 clogging the system parts

P0011695 3

Exhaust temperature sensor

Exhaust temperature sensor consists of a PT-200
sensor (200Ω 0°C) where the resistance changes
depending on exhaust temperature. The resistance
increases with rising exhaust temperature. The SCR-
catalyst temperature is calculated by the EMS uses
the value from the exhaust temperature sensor.

P0013504

Solenoid valve (AdBlue tank warm-up)

The UDS2 checks the temperature of the AdBlue sol-
ution using the tank temperature sensor. If the tem-
perature is < 10°C (50°F) the solenoid valve opens
and hot engine coolant flows through the hoses heat-
ing up the AdBlue. When the temperature inside the
AdBlue tank reaches 15°C (59°F) the solenoid valve
shuts-off and the heating flow to the tank stops. Can
be open/closed by vodia.

NOTICE! The solenoid valve must be mounted verti-

P0011694 cally, (solenoid on top) as shown on the picture.

47702556 02-2012 29
30-0 General

NOx sensor

1 The smart NOx sensor measures the NOx concen-

tration, air/fuel ratio and equilibrium oxygen partial
4 pressure in the exhaust gas of combustion engines.
The NOx sensor system, consists of a ceramic sen-
sor and an interface (board).The NOx-sensor inter-
3 face (board) provides the power control for heating
2 the sensor element to operating temperature of
800°C. The determine NOx concentration is realized
P0011677 as a binary signal and is provided digitally via J1939
(CAN bus 2) on pin 1 and pin 2. NOTE! The NOx
sensor system power supply is provided directly from
the battery and is not supplied from the UDS2.

Electric heated hoses and filter

P0012374

The AdBlue hoses are electrically heated by a thin - Heater hose FROM ADBLUE TANK
wire that is wrapped around the hose. To avoid
- Heater hose TO DOSING MODULE
damages on the heating system, the hoses must be
handled carefully and not be bent or turned substan- - Heater hose FROM DOSING MODULE
tial.
- Heater hose TO ADBLUE TANK
- Heater ADBLUE FILTER

30 47702556 02-2012
 30-0 General

Connection, electric heated hoses

Connection UDS2 (4)
Connections for electrical heated hoses (3)
A Connection from dosing module
(Return line / Backflow)
B
A B Connection from AdBlue tank
(Suction line)
3 D 3
C C Connection to dosing module
(Pressure line)
D Connection to AdBlue tank
4 (Return line / Backflow)

P0012684

Main cable harness SCR system

7 8

5 6 4

2
3 9
10
1

P0012682

1 Level/temp for urea tank

2 Solenoid valve for engine coolant
3 Heating connections (4 connectors)
4 Pump unit (UDS2)
5 Bottom filter heater pump unit
6 SCR to engine
7 SCR to engine
8 NOx sensor interface
9 Exhaust temperature sensor
10 Dosing Module (AdBlue injector)

47702556 02-2012 31
30-0 General

2 3 4 SCR pump unit

1
The pump unit consist in generally of a pump, a filter
house and a control unit (UDS2, MID233)

Pump unit connections:

1 INLET, AdBlue, Tank->Pump unit — 9,5 mm
(connection hose marked with red and connection
end with grey)
2 BACKFLOW INLET, AdBlue, Dosing valve->
Pump unit — 9,5 mm (connection hose marked
with white and connection end with blue)

xxxxxxxx
3 OUTLET, AdBlue, Pump unit->Dosing valve — 8
mm (connection hose marked with black and con-
nection end with green)
4 BACKFLOW OUTLET, AdBlue, Pump unit->Tank
— 8 mm (connection hose marked with yellow
and connection end with black)
5 Ventilation plug for pressure testing (after service
6 7 work)
P0013653 5
6 Connection, UDS2 (MID233)
7 Filter heater

NOTICE! When handling AdBlue, it is very important

that all electrical connectors are protected well, if not
there is a risk that the Adblue will cause oxide that is
not possible to clean. Water and compressed air will
not help because Adblue oxide the metall itself. If a
connector has been in contact with Adblue, it must
be changed immediately to prevent the AdBlue from
"creeping" further into the cable harness, which hap-
pen with a speed of 0,6m/h.

The electrical pump is a 24V DC membrane

pump.Working pressure of the pump is 5 bar (500
kPa).

Available spareparts:
• Temperature sensor
• Pressure sensor
• Strainer (pump inlet)
• Filter (complete)

32 47702556 02-2012
 30-0 General

Filter house
AdBlue passes through a filter after being pressur-
ized by the membrane pump. This filter is located in
the pump unit. It consists of a paperfilter (1) that
cleans the AdBlue from dirtparticles. Together with
5 the filter itself, there are two porous rubber sealings
2 (2) that protects the filter house if the moistured filter-
paper would freeze in cold climate. The filter is
sealed with an o-ring (3). On the filter house lid (4) is
an electrical filter heater (5) mounted, it has a "fork"
1 connection. The electrical filter heater is dismounted
when replacing the filter.
6
NOTICE! It is not necessary to change the strainer
3 (6) by service intervals, clean it if necessary and
change it if there is any damages.
4
P0013655

SCR dosing valve (AdBlue injector)

The injection of AdBlue is done by the dosing valve
that is mounted in 30 degrees angle in condition to
the exhaust flow. The dosing valve consists of a
valve and a nozzle that injects AdBlue with 5 bar
(500 kPa) pressure into the exhausts before they are
entering the catalyst/muffler. The amount of AdBlue
that is being injected is controlled by the engine con-
trol unit (EMS) and governed by engine load, rpm:s
and exhaust temperature. The injection is not acti-
vated if the AdBlue temperature is lower than -7 °C
or higher than 85 °C. The dosing valve is a magnetic
valve that is PWM (Pulse Width Modulation) control-
led. The dosing valve is protected from the hot
exhausts by a shield. The metal body is cooled down
p0013248
by circulating AdBlue that has a maximum tempera-
ture of 85 °C. The dosing valve is mounted so the
connection cable is kept away from the muffler. The
shield is marked with Volvo item number and vendor
serial number for identification of which type of dos-
ing valve that is mounted. There are two types of
dosing valves; 6 kg/h respective 9 kg/h, please check
with Volvo Parts incase of item number updates.

The connections have different dimensions so they

are not switched.

INLET = 8 mm (black) and OUTLET = 9,5 mm

(black).

Run VODIA test "dosing test" to test the dosing valve

funktion.
P0013658 NOTICE! The dosing valve is a sensitive component
that must be handled carefully by service work.

47702556 02-2012 33
30-0 General

A A
A + A = OK

B + B = OK

A + A = OK
2
2

B + B = OK
B B
p0013246

SCR-Catalyst (muffler)
The exhausts are led into the SCR-catalyst that is
integraded into the muffler. The catalyst consists of a
ceramic structure with several small canals covered
with an active substance. AdBlue is injected into the
exhaust pipe just before the catalyst and is mixed
with the hot exhausts. By the high temperature the
AdBlue decomposes quick into amonia and carbon
dioxide. When the exhausts are passing the SCR-
catalyst it speeds up the reaction between amonia
and carbon dioxide in the exhausts, and the final
transformation becomes harmless nitrogen and
water. In the final step before exit the catalyst, there
is a platina coating that takes care of non-reacted
P0013659 amonia to prevent amonia smell of the exhausts.
External mounted component, such as NOx-sensor,
dosing valve and exhaust temperature sensor is
exchangable.

NOTICE! The SCR-catalyst can not be renovated or

separate changed, the complete muffler must be
changed when needed.

34 47702556 02-2012
 30-0 General

General advice on working with

EMS engines and UDS equipment
The following advice must be followed to avoid dam-
age to the engine control unit and other electronics.

IMPORTANT!
The system must be disconnected from system volt-
age (by cutting the current with the main switch) and
the starter key(s) must be in the 0 position when the
engine control unit connectors are disconnected or
connected.
• Never disconnect the current with the main
switches when an engine is running.
• Never undo a battery cable when the engine is
running.
• Turn the main switches off or disconnect the bat-
tery cables during quick charging of the batteries.
NOTICE! During normal trickle charging, it is not
necessary to turn the main switches off.
• Only batteries may be used for start help. A help
start device can produce a very high voltage and
damage the control unit and other electronics.
• If a connector is disconnected from a sensor, be
very careful to avoid allowing the contact pins to
come into contact with oil, water or dirt.

Electrical Welding
1 NOTICE! Cut the current with the main switch.

IMPORTANT!
The system must be disconnected from system
voltage when the engine control unit connectors
are disconnected or connected.
2 Undo the two connectors from the engine control
unit before any electrical welding starts. Turn the
locking arm down at the same time as the con-
nector is pulled outwards.
3 Disconnect all connections to the alternator.
Connect the welder earth clamp to the component
to be welded, or as close as possible to the weld
site. The clamp must never be connected to the
P0013966 engine or in such a way that current can pass
through a bearing.

IMPORTANT!
After welding is completed, the disconnected
components, such as alternator cables and bat-
tery cables must be connected in the correct
order.

The battery cables must always be connected

last.

47702556 02-2012 35
30-0 General

Reprogramming a control unit

IMPORTANT!
The CHASSIS ID number must be readily available
to allow the software to be downloaded.

Action:
1 Log in to Volvo Penta Partner Network’s website:
www.vppn.com
2 Choose “Service & Warranty > VODIA > ECU programming”.
3 Follow the instructions under “Select Chassis ID”.
Choose the control units to be reprogrammed and download the software.
The software for the control units is now downloaded to the PDA(1).
4 Take a look under “Settings”, “Software information” in VODIA to check that the
software has been downloaded.
5 Connect the VODIA to the engine (control unit) to be programmed.
6 Start with the engine control unit.
Select “Engine with mounting and equipment” in the VODIA menu.
Select “MID 128 Control unit, programming”.
VODIA will guide you through the entire programming process.
7 NOTICE! Programming must be reported back to Volvo Penta within 28 days.
Log in to Volvo Penta Partner Network’s web site (www.vppn.com).
8 Choose “VODIA” in the left-hand menu.
9 Choose “Report software” in the left-hand menu.
10 Follow the instructions for “Report software”.
Click “Report”.

1. PDA = “Personal Digital Assistant” (palmtop computer).

36 47702556 02-2012
 30-0 General

Programming an empty control

unit
When a new engine control unit is installed, where no
software has been downloaded, the control unit must
be programmed.

The new control unit must have the same part num-
ber as the old control unit. If the control units do not
have the same part number, it will not be possible to
program the new control unit until a “Conversion kit”
has been ordered from Volvo Penta.

If the control units have the same part number, the

new control unit can be programmed as usual.
Please refer to Reprogramming a control
unit page 36.

If the part numbers do not coincide – proceed as

possible:
1 Have both part numbers available.
2 Log in to Volvo Penta Partner Network’s web site:
www.vppn.com
3 Choose “Service & Warranty > VODIA > Conver-
sion kit / Accessory kit wizard”.
4 Select engine type and function.
5 Select conversion kit(s) and chassis ID.
6 All selections will be shown in a summary. Click
continue if they are correct.
7 Volvo Penta’s database is now updated. It can
take about a minute before a confirmation is sent.
8 Programming of the control unit can now start.
Please refer to Reprogramming a control
unit page 36.

47702556 02-2012 37
30-0 General

Fault tracing of cables and

connectors
Tools:
88890074 Multimeter
9998482 Measuring tool

Check all connectors visually

Check the following:

• Look for oxidation which can impair contact in con-
nectors.
• Check that terminals are undamaged, that they are
correctly inserted into their connectors, and that
the cable is correctly terminated in the terminal.
• Check that there is good mechanical contact in the
connector. Use a loose pin to check this.

IMPORTANT!
The multi-pin connectors for the engine control unit
must only be checked with 9998482 Measuring
tool.
• Carefully insert 9998482 Measuring tool into the
multi-pin connector. Pull and push the connector in
and out a few times and feel whether the terminal
socket grasps the tool. If the terminal socket does
not grasp, or if it feels slack, the connection pins
should be changed. Please refer to Joining electri-
cal cables for connectors. Check the secondary
locking in the connector.
• If possible, shake the cables and pull the connec-
tors 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 con-
nector.
• Check the function of the secondary locking.

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

Wear can also cause faults. For this reason, avoid

disconnecting a connector unless it is necessary.

Other contact problems can be caused by damage to

pins, sockets and connectors etc.

Shake cables and pull connectors during measure-

ment, to find where the cable is damaged.

38 47702556 02-2012
 30-0 General

Contact resistance and oxidation

Resistance in connectors, cables and junctions
should be approx. 0 Ω. A certain amount of resist-
ance 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 cables which

are relevant to the function. Start off with the most
probable cable in the circuit.

Check the following:

• Disconnect the relevant connector at each end of
the cable harness.
• Use 88890074 Multimeter to measure the resist-
ance between the ends of the cable.
Nominal value ~ 0 Ω.
• If possible, shake the cables and pull the connec-
tors during measurement to discover whether the
cable harness is damaged.
• Check the next cable system in the wiring sched-
ule if no fault has been found.

47702556 02-2012 39
30-0 General

SCR Vodia tests

1. SCR startup test

NOTICE! The engine and the SCR-system must
have a normal status with no active faultcodes to run
the tests without interference.

1 Connect the VODIA to the the diagnostic con-

nection on the engine (No separate connection
on the SCR-system)
2 Select function group "Engine" and then "Urea
Dosing System Tests", select "SCR startup
Test"
3 This test can force the SCR system to start with-
out starting the engine in order to check that a
newly installed, repaired or maintenanced sys-
tem is functional. The test checks that the cor-
rect system pressure of 5bar can be reached.
The test should not run longer than 2 minutes,
after that the test should be aborted by using
the stop bottom (If more than 2 minutes, check
the system, pressure can not be reached).
4 Preconditions; Engine off, Ignition on, Battery-
voltage > 20 V, Urea level in tank, Sufficient
urea solution temperature.
5 Sequence;
Start - Building up pressure - checking pressure
- finish.
6 Test message:
1 SCR startup Test is completed
2 SCR startup Test not completed
7 If test was not completed, check system. Pres-
sure (5 bar) can not be reached.

40 47702556 02-2012
 30-0 General

2. SCR dosing test

NOTICE! The engine and the SCR-system must
have a normal status with no active faultcodes to run
the tests without interference.

NOTICE! Before the measurement starts dosing test

must be performed with one of the three setups to
ensure that all lines are filled with urea before the
measurement start. The dosing test shall be per-
formed at room temperature The dosing test must
have the right setup options for motor type, if wrong
set up options is used, the test result will not be relia-
ble. All test setups 1-4 must be carried out to evalu-
ate the complete injector function.

Action:
1 Connect the VODIA to the the diagnostic con-
nection on the engine (No separate connection
on the SCR-system)
2 Select function group "Engine" and then "Urea
Dosing System Tests", select "SCR Dosing
Test"
3 This test determins if the correct amount of urea
solution is dosed depending on what application
that is identified (D5/D7 or D13/D16). Dosing
module adaptation D5/D7 6kg/h and D13/D16
9kg/h. The dosed amount of urea is measured
in milliliters (ml) by collecting the dosed urea
solution in a measuring glass. The test can also
be run in a mode (test set-up 0) where only the
signals to the dosing module are tested. In this
mode the dosing module does not need to be
dismounted.
4 TEST SETUP OPTIONS D13/D16:
1. Test setup 0 (20s, 0,02g)
2. Test setup 5 (120s, 200g)
3. Test setup 6 (360s, 54g)
4. Test setup 7 (120s, 300g)
TEST SETUP OPTIONS D5/D7:
1. Test setup 0 (20s, 0,02g)
2. Test setup 3 (120s, 100g)
3. Test setup 4 (360s, 37g)
4. Test setup 5 (120s, 200g)
5 Preconditions;
1 Remove the urea injector from the SCR
muffler before starting the test in order to
prevent damage to the catalyst
2 Start-up test must be run before this test
3 No leakage in the system
4 Engine off
5 Ignition on
6 Battery-voltage > 20 V

47702556 02-2012 41
30-0 General

7 Urea level in tank

8 Sufficient urea solution temperature
6 Sequence;
Start - Building up pressure - checking dosing -
releasing pressure - finish.
7 Test message:
SCR Dosing Test is completed. The dosing
module should be remounted and the engine
should be started, run at idle for a while and
shut off. This will ensure sufficient post ventila-
tion of the UDS, Fault codes should be read out
and faultcode MID128 PSID229 FMI9 "SAE
J1939 Data Link, SubNet 1, MID 233" should be
erased if present.
8 Exit dosing test

Test result evaluation

TEST SETUP OPTIONS D13/D16 (9kg/h): TEST SETUP OPTIONS D5/D7 (6kg/h):

Test setup 0 (20s, 0,02g) Test setup 0 (20s, 0,02g)

Only injector function tested Only injector function tested

Test setup 5 (120s, 200g = 6060g/h) Test setup 3 (120s, 100g = 3030g/h)
Measured level referens 170 - 200ml Measured level referens 85 - 100ml

Test setup 6 (360s, 54g = 540g/h) Test setup 4 (360s, 37g = 370g/h)
Measured level referens 44 - 55ml Measured level referens 30 - 38ml

Test setup 7 (120s, 300g = 9090kg/h) Test setup 5 (120s, 200g = 6060g/h)
Measured level referens 260 - 290ml Measured level referens 170 - 200ml

42 47702556 02-2012
 30-0 General

3. SCR Tank Heater Valve Test

NOTICE! The engine and the SCR-system must
have a normal status with no active faultcodes to run
the tests without interference.

Action:
1 Connect the VODIA to the the diagnostic con-
nection on the engine (No separate connection
on the SCR-system)
2 Select function group "Engine" and then "Urea
Dosing System Tests", select "SCR Tank
Heater Valve Test"
3 The test opens and closes the tank heating
valve (engine cooling water). Only the electrical
function is tested, not the mechanical valve
funktion.
4 Preconditions;
Engine off, Ignition on, Battery-voltage > 20 V.
5 Sequence;
Open - Close
6 Test message:
1 Open: Valve power stage activated
2 Close: Valve power stage deactivated
7 NOTICE! If tank heater valve is not closed after
finishing test, it will automatically close with igni-
tion off.

47702556 02-2012 43
30-0 General

4. Frozen cycle counters

NOTICE! The engine and the SCR-system must
have a normal status with no active faultcodes to run
the tests without interference.

NOTICE! If the frozen cycle counter reaches a value

of 1000 engins starts below a value of -10 °C on the
exhaust temperature sensor, it will trigger MID128,
PSID89, FMI14 that is only visible in vodia. Clear the
counter (see action nr. 5) and the faultcode is deacti-
vated. The function is used for conclude the function-
ality of the AdBlue dosing valve that may be harmed
due to hot exhausts when cooling circulation has
been limited.

Action:
1 Connect the VODIA to the the diagnostic con-
nection on the engine (No separate connection
on the SCR-system)
2 Select function group "Engine" and then "Urea
Dosing System Tests", select "Frozen cycle
counters"
3 The dosing module is deteriorated if urea solu-
tion freezes inside it. This test checks the status
of the dosing module based on two counters
that are incremented at startup in low tempera-
tures. The counters keep track of the number of
startups with frozen urea solution in the dosing
module, but also the number of startups with a
completely drained system at low temperatures.
4 No preconditions
5 Sequence;
READ: Reads out the values
CLEAR: Clear the values (not possible to undo)
6 Test message:
1 FCC1 (Frozen Cycle Counter 1), Number
of cold starts with drained system.
2 FCC2 (Frozen Cycle Counter 2), Number
of cold starts with undrained system.

44 47702556 02-2012
 30-0 General

5. Forced blowout
NOTICE! The engine and the SCR-system must
have a normal status with no active faultcodes to run
the tests without interference.

Action:
1 Connect the VODIA to the the diagnostic con-
nection on the engine (No separate connection
on the SCR-system)
2 Select function group "Engine" and then "Urea
Dosing System Tests", select "Forced blowout"
3 The test, forced blowout makes sure that the
system is completely drained from urea solution.
Normally the system drains itself after ignition
off by performing an after-run sequence. After
the forced blowout test, the UDS2 will shut
down and the communication stops, this results
in a fault code, MID128 PSID229 FMI9 "SAE
J1939 Data Link, SubNet 1, MID233", follow test
instruction to reset faultcode.
4 Preconditions;
Engine off, Ignition on, Battery-voltage > 20 V.
5 Sequence;
Start - Blowout ongoing - Finish
6 Test message:
1 OK, Forced blowout test completed
7 Sequence;
Turn ignition off - Wait 5 seconds - Turn ignition
on (EMS shut down)

47702556 02-2012 45
30-0 General

6. Derate reset DEF quality

NOTICE! The engine and the SCR-system must
have a normal status with no active faultcodes to run
the tests without interference.

Action:
1 Connect the VODIA to the the diagnostic con-
nection on the engine (No separate connection
on the SCR-system)
2 Select function group "Engine" and then "Urea
Dosing System Tests", select "Derate reset DEF
quality"
3 This operation resets the active engine derate.
The system has detected poor AdBlue/DEF
quality when evaluating injected amount with
emissions. Before resetting the derate a full sys-
tem overview must be preformed, including
AdBlue/DEF check and dosing test.
4 Preconditions;
Engine off, Ignition on, Battery-voltage > 20 V,
Performed AdBlue/DEF check, Performed dos-
ing test, Clear fault code MID128 PSID90.
5 Select Derate reset
6 Test message:
1 Active engine derate deactivated success-
fully
2 Active engine derate deactivation failed
- Could not find MID 128
- Could not find derate parameter
- Could not set derate parameter
- Could not program derate parameter

46 47702556 02-2012
 30-0 General

SCR Vodia log test

NOTICE! The engine and the SCR-system must
have a normal status with no active faultcodes.

NOTICE! Aftertreatment regent filter temperature not

avalible on UDS2 version.

Action:
1 Connect the VODIA to the the diagnostic con-
nection on the engine
(No separate connection on the SCR-system)
2 Select function group “service and mainte-
nance” and then “LogTest”.
3 Select “Main data List”
(No availible SCR template)
4 Availible SCR specific parameters:

1. MID 128 Throttle position (0 - 100 %)

2. MID 128 NOx sensor gas outlet (0 - 510
ppm)
3. MID 128 Relative air humidity (0 - 100 %)
4. MID 128 Air temperature for humidity
(- 40 - 100 °C)
5. MID 128 Aftertreatment reagent pressure
(0 - 5 bar)
6. MID 128 Aftertreatment reagent tank temper-
ature (- 40 - 100 °C)
7. MID 128 Aftertreatment reagent level
(0 - 1020 mm)
8. MID 128 Exhaust gas temperature sensor #1
(- 40 - 1100 °C)
9. MID 128 Total aftertreatment reagent used
(0 - N/A L)
10. MID 128 Catalyst Use information (N/A)
Measured use of reagent by a
Selective Catalytic Reduc tion sys-
tem for exhaust emission control,
averaged over the previous 15
hours of engine operation.
Resolution: 0,05 l/h

47702556 02-2012 47
30-2 Fault Tracing

30-2 Fault Tracing

Fault Codes
MID 128, PID 51 Throttle Position

MID 128: Engine control unit

FMI 2 – Data erratic, intermittent or incorrect

Fault code explanation: Plausability (TAD560-561VE, TAD761-765VE).
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: Actual throttle position compared with requested throttle position (deviation
detected).
Possible reason: • Short circuit to positive side.
• Faulty harness.
• Faulty throttle.
Suitable action: 1 Check the cables and the connectors between the sensor and the
EMS.
2 Check the throttle.
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

FMI 3 – Voltage above normal or shorted high

Fault code explanation: Short circuit to positive side.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display
• DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: Voltage value >4,7V on the EMS pin EB24 (sensor pin 5)
Possible reason: • Short circuit to positive side.
• Faulty harness.
• Faulty throttle.
Suitable action: 1 Check the cables and the connectors between the sensor and the
EMS.
2 Check the throttle
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

48 47702556 02-2012
 30-2 Fault Tracing

FMI 4 – Voltage below normal or shorted to lower voltage

Fault code explanation: Short circuit to negative side
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: Short circuit to negative side
Possible reason: • Short circuit to negative side
• Open Circuit
• Faulty harness.
• Faulty throttle.
Suitable action: 1 Check the cables and the connectors between the sensor and the
EMS.
2 Check the throttle
Measurements: • Checking the throttle mechanical position page 114
• Checking the throttle motor page 114

FMI 5 – Voltage below normal or shorted to lower voltage.

Fault code explanation: Open circuit / Short circuit to negative side
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: < 0,3 V
Possible reason: • Short circuit to negative side
• Open Circuit
• Faulty harness.
• Faulty throttle.
Suitable action: 1 Check the cables and the connectors between the sensor and the
EMS.
2 Check the throttle
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

47702556 02-2012 49
30-2 Fault Tracing

FMI 7 – Mechanical system is not responding properly

Fault code explanation: Mechanical fault (maximum time limit)
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: Mechanical fault (maximum time limit)
Possible reason: • Faulty throttle.
• Throttle valve stucked
• Wrong current
Suitable action: 1 Check the throttle
2 Check the mechanical throttle position
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

FMI 11 – Unidentifiable error

Fault code explanation: Out of calibration (open above max, ex 105%)
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: Out of calibration (open above max, ex 105%)
Possible reason: • Faulty throttle.
• H-bridge throttle position
Suitable action: 1 Check the throttle
2 Check the mechanical throttle position
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

50 47702556 02-2012
 30-2 Fault Tracing

FMI 12 – Faulty device or component

Fault code explanation: Out of calibration (open below min, ex 95%)
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: Out of calibration (open below min, ex 95%)
Possible reason: • Faulty throttle.
• H-bridge throttle position
Suitable action: 1 Check the throttle
2 Check the mechanical throttle position
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

FMI 13 – Calibration value out of range

Fault code explanation: Out of calibration (closed above max, ex 5%)
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: Out of calibration (closed above max, ex 5%)
Possible reason: • Faulty throttle.
• H-bridge throttle position
Suitable action: 1 Check the throttle
2 Check the mechanical throttle position
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

47702556 02-2012 51
30-2 Fault Tracing

FMI 14 – Special instructions

Fault code explanation: Out of calibration (closed below min, ex -5%)
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: Out of calibration (closed below min, ex -5%)
Possible reason: • Faulty throttle.
• H-bridge throttle position
Suitable action: 1 Check the throttle
2 Check the mechanical throttle position
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

52 47702556 02-2012
 30-2 Fault Tracing

Circuit description
The throttle position sensor is a Hall effect generator.
The working range is between 0,5 V to 4,4 V and
starts with a closed throttle up to fully open. The out-
put from the sensor is linear (output voltage / % open
throttle). Position accuracy is +-0,1 degree.The
engine control unit uses the sensor signal to calcu-
late the throttle position. When the throttle gets the
order to turn, the EMS sets +24V on pin EB1 (open)
or pin EB5 (close). Each time by key on, the throttle
run a calibration cycle for checking the valve position.

Sensor EMS2 Signal type

Pin 1 EB5 Motor voltage 1
Pin 2 EB17 (spline 7) Supply voltage 5 V
(throttle position)
Pin 3 EB18 (spline 8) Battery negative
(ground throttle posi-
tion)
Pin 4 EB1 Motor voltage 2
Pin 5 EB24 Output throttle position
(H-bridge)

Component location
The air throttle is located on the engine air intake.

CAUTION!
Pinch hazard. Keep fingers clear.

P0014415

Output throttle position

P0010764

P0010765

47702556 02-2012 53
30-2 Fault Tracing

MID 128, PID 354 Relative Humidity

MID 128: Engine control unit

FMI 3 – Voltage above normal or shorted high

Fault code explanation: • Short circuit to positive side, meassuring line
• Open circuit negative side
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Humidity is set to 50%
Conditions for fault code: • Short circuit to positive side, meassuring line
• Open circuit negative side
Possible reason: • Faulty connector
• Faulty harness
• Faulty sensor
Suitable action: 1 Check the cables and the connectors between the sensor and the
EMS.
2 Check for sources that could cause interferrence.
3 Check the sensor.
Measurements: Checking the combinated relative humidity and temperature
sensor page 115

FMI 5 – Current below normal or open circuit

Fault code explanation: • Open circuit, meassuring line
• Open circuit 5V
• Short circuit negative side, meassuring line
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Humidity is set to 50%
Conditions for fault code: • Open circuit, meassuring line
• Open circuit 5V
• Short circuit negative side, meassuring line
Possible reason: • Open circuit in sensor supply cable.
• Open circuit in sensor signal cable.
• Short circuited sensor signal cable to sensor negative cable.
• Faulty sensor
Suitable action: 1 Check the cables and the connectors between the sensor and the
EMS.
2 Check for sources that could cause interferrence.
3 Check the sensor.
Measurements: Checking the combinated relative humidity and temperature
sensor page 115

54 47702556 02-2012
 30-2 Fault Tracing

Circuit description
The sensor is combined for relative humidity and
temperature measurement on the air intake. The
EMS via the UDS2 uses the input signals to compen-
sate the AdBlue dosing strategi. The sensor is not
used on the 5L & 7L Deutz Tier 4 engines.
The relative humidity (%RH) delivers an analog sig-
nal in proportion to Humidity. The output from the
sensor pin 2 is linear 0,5-5V from 0-100%RH. The
temperature (°C) delivers a recistance output on pin
4. R at 25°C = 10kΩ

Sensor EMS2 Signal type

Pin 1 EA7(splice2) Supply voltage +5V
Pin 2 EA23 Output 0,5-4,5V
(Humidity)
Pin 3 EA11(splice1) Batt negative (GND)
Pin 4 EA43 Output resistance
(temp.)

Component location
The combined relative humidity and temperature
sensor is located on the engines air intake.

P0010772

P0011692

47702556 02-2012 55
30-2 Fault Tracing

MID 128, PPID 270 NOx Sensor Gas

Outlet

MID 128: Engine control unit

FMI 2 – Data erratic, intermittent or incorrect

Fault code explanation: Plausability / Sensor removed
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: Engine derate, see Electrical Power Supply, Lightning, Instruments,
Software page 140
Conditions for fault code: • Deviation detected
• No emissions measured over a certain time
Possible reason: • Exhaust system leakage
• Air intake leakage
• Faulty NOx sensor
Suitable action: 1 Check that the NOx-sensor is correctly installed and clean.
2 Check the cables and the connectors between the NOx-sensor, NOx-
sensor board and connection harness
3 Check the air intake
4 Check the exhaust system
5 Check the NOx-sensor.
Measurements: Checking the NOx-sensor page 117

FMI 3 – Voltage above normal or shorted high

Fault code explanation: Short circuit sensor signal
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: None.
Conditions for fault code: Short circuit NOx signal (Ignition on)
Possible reason: • Short circuited sensor signal cable to sensor negative cable.
• Short circuited sensor signal cable to sensor positive cable.
• Check cables between sensor interface and sensor.
Suitable action: 1 Check that the NOx-sensor is correctly installed and clean.
2 Check the cables and the connectors between the NOx-sensor, NOx-
sensor board and connection harness
Measurements: Checking the NOx-sensor page 117

56 47702556 02-2012
 30-2 Fault Tracing

FMI 5 – Current below normal or open circuit

Fault code explanation: Open circuit sensor signal
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: None.
Conditions for fault code: Open circuit NOx signal (Ignition on)
Possible reason: • Short circuited sensor signal cable to sensor negative cable.
• Short circuited sensor signal cable to sensor positive cable.
• Check cables between sensor interface and sensor.
• Fuse EATS
Suitable action: 1 Check that the NOx-sensor is correctly installed and clean.
2 Check the cables and the connectors between the NOx-sensor, NOx-
sensor board and connection harness
3 Check the NOx-sensor.
Measurements: Checking the NOx-sensor page 117

FMI 9 – Abnormal update rate

Fault code explanation: Abnormal update
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: Engine derate, see Electrical Power Supply, Lightning, Instruments,
Software page 140
Conditions for fault code: • Abnormal update / Missing signal
• Deviation between mapped emissions and actual value
Possible reason: • Faulty NOx sensor
• Fuse EATS (Can-link J1939 is down)
• 24V power supply NOx sensor
Suitable action: 1 Check that the NOx-sensor is correctly installed and clean.
2 Check the cables and the connectors between the NOx-sensor, NOx-
sensor board and connection harness
3 Change the NOx sensor
Measurements: Checking the NOx-sensor page 117

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30-2 Fault Tracing

FMI 12 – Faulty device or component

Fault code explanation: Incorrect value
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: None.
Conditions for fault code: • NOx-sensor signal corrupt for 10 min
• Monitoring the quality of the NOx level signal
Possible reason: • Faulty NOx sensor
Suitable action: 1 Check that the NOx-sensor is correctly installed and clean.
2 Check the cables and the connectors between the NOx-sensor, NOx-
sensor board and connection harness
Measurements: Checking the NOx-sensor page 117

FMI 14 – Special instructions

Fault code explanation: Message from sensor due to voltage batteri
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: None.
Conditions for fault code: • To high voltage supply to NOx-sensor. (Message from NOx-sensor
due to VBatt)
• Above 32V for more than 1min
Possible reason: • Voltage supply from engine / batteries
Suitable action: 1 Check voltage supply from engine / batteries

58 47702556 02-2012
 30-2 Fault Tracing

Circuit description
The NOx sensor system, consists of a ceramic sen-
sor and an interface (board).The NOx-sensor inter-
face (board) provides the power control for heating
the sensor element to operating temperature of
800°C. The determine NOx concentration is realized
as a binary signal and is provided digitally via J1939
(CAN bus 2) on pin 1 and pin 2.
3: GND 2: CAN_low
4: Ubatt NOTICE! The NOx sensor power supply is provided
1: CAN_high directly from the battery.

Sensor UDS 2 Signal type

32,3

Pin 1 5 (splice 5) Can H J1939

24,3

Pin 2 6 (splice 6) Can L J1939

Pin 3 Bat -
P0011682 Pin 4 Bat +24V

Component location
The NOx-sensor is located at the side of the muffler.
There are variations of mufflers depending on motor
type so the position can be different

A
B

P0012689

1
4

3
2

P0011677

1 NOx sensor interface

2 NOx sensor cable entrence
3 NOx sensor cable
4 NOx sensor measurement body

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30-2 Fault Tracing

MID 128, PPID 272 Air temperature

for humidity compensation

MID 128: Engine control unit

FMI 4 – Voltage below normal or shorted to lower voltage

Fault code explanation: Short circuit to battery negative side
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Temperature is set to 20 °C
Conditions for fault code: Short circuit to negative side
Possible reason: • Faulty connector
• Faulty harness
• Faulty sensor
Suitable action: 1 Check the cables and the connectors between the sensor and the
EMS.
2 Check for sources that could cause interferrence.
3 Check the sensor.
Measurements: Checking the combinated relative humidity and temperature
sensor page 115

FMI 5 – Current below normal or open circuit

Fault code explanation: Short circuit to battery pos / Open Circuit
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: Temperature is set to 20 °C
Conditions for fault code: • Short circuit to positive side.
• Open Circuit
Possible reason: • Faulty connector
• Faulty harness
• Faulty sensor
Suitable action: 1 Check the cables and the connectors between the sensor and the
EMS.
2 Check for sources that could cause interferrence.
3 Check the sensor.
Measurements: Checking the combinated relative humidity and temperature
sensor page 115

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Circuit description
The sensor is combined for relative humidity and
temperature measurement on the air intake. The
EMS via the UDS2 uses the input signals to compen-
sate the AdBlue dosing strategy. The sensor is not
used on the 5L & 7L Deutz Tier 4 engines.
The relative humidity (%RH) delivers an analog sig-
nal in proportion to Humidity. The output from the
sensor pin 2 is linear 0,5-5V from 0-100%RH. The
temperature (°C) delivers a resistance on pin 4. R at
25°C = 10kΩ

Sensor EMS2 Signal type

Pin 1 EA7(splice2) Supply voltage +5V
Pin 2 EA23 Output 0,5-4,5V
(Humidity)
Pin 3 EA11(splice1) Batt negative (GND)
Pin 4 EA43 Output resistance
(temp.)

Component location
The combined relative humidity and temperature
sensor is located on the engines air intake.

P0011692

P0010772

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MID 128, PPID 273 Aftertreatment

Reagent Pressure

MID 128: Engine control unit

FMI 1 – Data valid but below operational range

Fault code explanation: Leakage.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate/shutdown red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate/shutdown red light)
Symptom: Engine derate, see Electrical Power Supply, Lightning, Instruments,
Software page 140.
Conditions for fault code: No AdBlue dosing / N/A.
Possible reason: • Empty tank.
• AdBlue filter.
• AdBlue hose.
• Dosing valve.
Suitable action: 1 Check parts above.

FMI 2 – Data erratic, intermittent or incorrect

Fault code explanation: Plausibility.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate/shutdown red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate/shutdown red light)
Symptom: None.
Conditions for fault code: Sensor tested during start-up, difference between Adblue pressure and
ambient pressure above limit.
Possible reason: • Faulty sensor.
Suitable action: 1 Check all the cables and connectors to the sensor.
2 Check the sensor.
Measurements: Checking the aftertreatment reagent pressure sensor page 118.

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FMI 4 – Voltage below normal or shorted to lower voltage

Fault code explanation: Short circuit to battery negative.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate/shutdown red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate/shutdown red light)
Symptom: None.
Conditions for fault code: < 0,15 V
Possible reason: • Short circuited sensor supply cable to sensor signal cable.
• Short circuited sensor supply cable to sensor negative cable.
• Faulty sensor.
Suitable action: 1 Check all the cables and connectors to the sensor.
2 Check the sensor.
Measurements: Checking the aftertreatment reagent pressure sensor page 118.

FMI 5 – Current below normal or open circuit

Fault code explanation: Open Circuit.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate/shutdown red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate/shutdown red light)
Symptom: Engine derate, see Electrical Power Supply, Lightning, Instruments,
Software page 140.
Conditions for fault code: > 4,95 V
Possible reason: • Open circuit in sensor supply cable.
• Open circuit in sensor negative cable.
• Open circuit in sensor signal cable.
• Faulty sensor.
Suitable action: 1 Check all the cables and connectors to the sensor.
2 Check the sensor.
Measurements: Checking the aftertreatment reagent pressure sensor page 118.

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FMI 7 – Mechanical system not responding properly

Fault code explanation: Build up failure.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate/shutdown red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate/shutdown red light)
Symptom: Engine derate, see Electrical Power Supply, Lightning, Instruments,
Software page 140.
Conditions for fault code: • < 2,83bar kPa after 75sec with running pump.
• Pressure build-up problem.
Possible reason: • Empty AdBlue tank.
• AdBlue filter clogged.
• AdBlue inlet pipe leakage/blocked.
• AdBlue tank ventilation.
• Pump unit.
• Faulty sensor.
Suitable action: 1 Check all the cables and connectors to the sensor.
2 Check the sensor.
3 See above on possible reasons.
Measurements: Checking the aftertreatment reagent pressure sensor page 118.

FMI 9 – Abnormal update rate

Fault code explanation: Engine protection derate.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate/shutdown red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate/shutdown red light)
Symptom: Engine protection derate.
Conditions for fault code: • Engine protection derate.
(Depending on application mapping)
• No Adblue injector cooling circuit.
Possible reason: • Build up pressure.
• No AdBlue cooling flow.
Suitable action: 1 Check the complete AdBlue circuit.
2 Check filter and strainers suction/pressure line.
3 Check for possible leakage.

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FMI 10 – Abnormally large variations

Fault code explanation: Engine protection shutdown.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate/shutdown red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate/shutdown red light)
Symptom: Engine protection shutdown.
Conditions for fault code: • Engine protection shutdown.
(Depending on application mapping)
• No Adblue injector cooling circuit.
Possible reason: • Build up pressure.
• No AdBlue cooling flow.
Suitable action: 1 Check the complete AdBlue circuit.
2 Check filter and strainers suction/pressure line.
3 Check for possible leakage.

FMI 13 – Calibration value out of range

Fault code explanation: Electrical failure.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate/shutdown red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate/shutdown red light)
Symptom: None.
Conditions for fault code: Voltage below 4.5 V or above 5.5 V.
Possible reason: • Faulty sensor.
• Faulty UDS2.
Suitable action: 1 Check the sensor.
2 If sensor is faulty:
Replace the sensor.

If sensor is not faulty:

Change UDS2 (pump unit).
Measurements: Checking the aftertreatment reagent pressure sensor page 118.

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FMI 14 – Calibration value out of range

Fault code explanation: Heating Failure.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate/shutdown red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate/shutdown red light)
Symptom: None.
Conditions for fault code: • Heating Failure.
• SPN 4355 Filter heater filter top (internal UDS2).
• SPN 4356 Backflow heater (internal UDS2).
• SPN 2061 Filter heater bottom (external).
Possible reason: • Open circuit in heater supply cable.
• Short circuited heater supply cable to sensor negative cable.
• Short circuited heater supply cable to sensor positive cable.
• Faulty heater.
Suitable action: 1 Check all the cables and connectors between the heater and the
UDS2. (internal UDS2).
2 Check all the cables and connectors between the heater and the
main cable harness. (external)
3 Check the heater.
Measurements: Checking the heaters (not electric heated hoses) page 119.

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Circuit description
The aftertreatment reagent pressure sensor measure
the AdBlue pressure after the pump. The sensor is
with a 3-pin connector (Supply voltage, GND, Output
voltage). The sensor is supplied internal from the
UDS2 and the output voltage from the sensor to the
UDS2 is feedback that is translated into the status
pressure. Working range 0 - 5 bar. Approximately
output voltage value 0,7 - 2,9 V. When starting up it
will try to build up pressure (3 x 4 minutes, incl. after-
run) and this function is mainly used for starting up
the SCR-system in cold climate.

Sensor UDS2 Signal type

Pin 1 Supply voltage +5V
Pin 2 Batt negative (GND)
Pin 3 Output voltage (pres-
sure)

Component location
The AdBlue pressure sensor is located inside the
pump unit under the top cover. It is mounted on the
top of the filter house.

NOTICE! When opening the cover of the pump unit,

the pump unit must be checked so it is completely
sealed when service work is finished. Use pressure
test pump 88890104 and pressure test nipple
88890102.

p0013263

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MID 128, PPID 274 After-treatment

Reagent Tank Temperature

MID 128: Engine control unit

FMI 0 – Data valid but above normal operational range

Fault code explanation: Reagent temperature too high
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: None.
Conditions for fault code: AdBlue temperature above 84°C in normal operating
Possible reason: • Heater valve stucked in open position
Suitable action: 1 Check that the valve is correctly installed
2 Check the AdBlue tank temp/level sensor
3 Check the cables and the connectors to valve
4 Run vodia test for aftertreatment regent tank heating valve. (open /
close)
Measurements: Checking the aftertreatment reagent tank temperature and level
sensor page 122

FMI 1 – Data valid but below operational range

Fault code explanation: Reagent temperature too low
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: No AdBlue dosing
Conditions for fault code: No heating of AdBlue tank.
PSID 75 (Aftertreatment regent tank heating valve) FMI 3 (voltage above
normal or shorted to high) and FMI 5 (open circuit) shold be active.
Possible reason: • Electrical error on heating valve
• Open circuit in sensor negative cable
• Open circuit in sensor supply cable
• Voltage above normal or shorted to high
• Valve connector
• Valve stucked in closed position
Suitable action: 1 Check that the valve is correctly installed
2 Check the cables and the connectors to valve
3 Run vodia test for aftertreatment regent tank heating valve. (open /
close)

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FMI 4 – Voltage below normal or shorted to lower voltage

Fault code explanation: Short circuit to battery negative.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: None.
Conditions for fault code: < 0,98 V for more than 5 sec
Possible reason: • AdBlue tank temp sensor
• Faulty harness
• Connector tank temp sensor
Suitable action: 1 Check that the valve is correctly installed
2 Check the cables and the connectors to valve

FMI 5 – Current below normal or open circuit

Fault code explanation: Open Circuit
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: None.
Conditions for fault code: > 4,85 V for more than 5 sec
Possible reason: • AdBlue tank temp sensor
• Faulty harness
• Connector tank temp sensor
Suitable action: 1 Check that the valve is correctly installed
2 Check the cables and the connectors to valve
3 Run vodia test for AdBlue tank heating valve. (open / close)

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Circuit description
The sensor is combined for temperature and level
measurement inside the AdBlue tank. The level sen-
sor delivers an voltage output on pin 2 0,5-4,5V from
48-320mm (20/50L tank volume).Tolerance float
decending ± 5mm. The temperature (°C) delivers a
resistance output on pin 3.

Sensor UDS2 Signal type

Pin 1 30 Supply voltage +5V
Pin 2 18 Output 0-4,5V (Level)
Pin 3 29 Output resistance
(temp.)
Pin 4 19 Batt negative (GND)

Component location
The AdBlue tank heating valve have variations of
locations depending on the application and installa-
tion. On the original Volvo Penta AdBlue tank the
level/temp. sensor is fitted inside the tank, connected
2 from the top. The combinated temperature and level
sensor is located inide the AdBlue tank with the con-
nections visible at the top.

P0011695 3

P0011694

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MID 128, PPID 275 After-treatment

Reagent Filter Temperature

MID 128: Engine control unit

FMI 0 – Data valid but above normal operational range

Fault code explanation: Reagent filter temperature too high
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: None.
Conditions for fault code: AdBlue reagent temperature > 85 °C for 10 sec
Possible reason: • AdBlue temperature in tank
• Faulty temperature sensor.
• AdBlue heater valve stuck in open position
• Faulty pump unit, filter heating does not shut off
Suitable action: 1 Check the cables and the connectors to valve
2 Run vodia test for aftertreatment reagent tank heating valve. (open /
close)
3 Check the cables and the connectors to the sensor.

FMI 1 – Data valid but below operational range

Fault code explanation: Reagent filter temperature too low / Electrical heating not possible
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: None.
Conditions for fault code: Heater failure when ambient filter temperature < -5 °C
Possible reason: • Electrical fault on one or more of the heaters
Suitable action: 1 Check all the cables and connectors on the elecrtical heaters: 1-
Heater from tank to pump unit, 2-Heater to AdBlue injector, 3-Heater
from AdBlue injector, 4-Heater to tank, 5-Heater AdBlue filter (on the
top inside pump unit and bottom)

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FMI 2 – Data erratic, intermittent or incorrect

Fault code explanation: Value out of operating range
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: None.
Conditions for fault code: AdBlue filter temperature < -9 °C even though the system is heated and up
and running or filter temperature > -84 °C
Possible reason: • Aftertreatment reagent tank heating valve stuck in closed or open
position
Suitable action: 1 Check that the valve is correctly installed
2 Check the cables and the connectors to valve
3 Run vodia test for aftertreatment regent tank heating valve. (open /
close)

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Circuit description
The aftertreatment reagent filter temperature sensor
is measuring the AdBlue system temperature. The
sensor is controlling the internal heating; the four
elecric heated hoses (from tank, to injector, from
injector, to tank), top filter heater, bottom filter heater
and tin-plate heater on backflow. The sensor feed-
back is handle internally by the UDS2, voltage output
is transformed into a temperature value. The sensor
value can not be shown as a VODIA log parameter
on the UDS2 version.

Sensor UDS2 Signal type

Pin 1 Supply voltage +5V
Pin 2 Batt negative (GND)

Component location
The aftertreatment reagent filter temperature sensor
is located in the pump unit on top of the filter houses
right side

NOTICE! When opening the cover of the pump unit,

the pump unit must be checked so it is completely
sealed when service work is finished. Use pressure
test pump 88890104 and pressure test nipple
88890102.

p0013260

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MID 128, PPID 278 After-treatment

Reagent Level

MID 128: Engine control unit

FMI 3 – Voltage above normal or shorted high

Fault code explanation: Short circuit positive side
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: Dosing continues, PPID273 FMI 7 can follow if tank becomes empty
Conditions for fault code: > 4,648 V
Possible reason: • Faulty sensor
• Cables and the connector to the sensor
Suitable action: 1 Check that the sensor is correctly installed
2 Check the cables and the connector to the sensor
3 Check the sensor.
4 Check Vodia logparameter, Aftertreatment reagent level
Measurements: Checking the aftertreatment reagent tank temperature and level
sensor page 122

FMI 5 – Current below normal or open circuit

Fault code explanation: Open Circuit / Short circuit negative side
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: None.
Conditions for fault code: • Open Circuit
• Short circuit to negative side
Possible reason: • Open circuit in sensor supply cable.
• Open circuit in sensor signal cable.
• Short circuited sensor signal cable to sensor negative cable.
• Faulty sensor.
Suitable action: 1 Check that the sensor is correctly installed
2 Check the cables and the connector to the sensor
3 Check the sensor
4 Check Vodia logparameter, Aftertreatment reagent level
Measurements: Checking the aftertreatment reagent tank temperature and level
sensor page 122

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FMI 11 – Unidentifiable error

Fault code explanation: Low level 1, warning
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: Warning to operator (typically10% left in tank)
Conditions for fault code: Warning to operator, 10% left in tank
Possible reason: • Low AdBlue level
• Cables and the connector to the sensor
• Faulty sensor
Suitable action: 1 Fill tank with AdBlue
2 Check that the sensor is correctly installed
3 Check the cables and the connector to the sensor
4 Check the sensor
5 Check Vodia logparameter, Aftertreatment reagent level
Measurements: Checking the aftertreatment reagent tank temperature and level
sensor page 122

FMI 13 – Calibration value out of range

Fault code explanation: Low level 2, cooling limited / Sensor voltage
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: None.
Conditions for fault code: Level voltage output < 520 mV for 120 sec
Possible reason: • Low AdBlue level
• Cables and the connector to the sensor
• Faulty sensor
Suitable action: 1 Fill tank with AdBlue
2 Check that the sensor is correctly installed
3 Check the cables and the connector to the sensor
4 Check the sensor
5 Check Vodia logparameter, Aftertreatment reagent level
Measurements: Checking the aftertreatment reagent tank temperature and level
sensor page 122

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FMI 14 – Special instructions

Fault code explanation: Low level 3, stop dosing AdBlue
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: No dosing, engine derate, see derate schedule
Conditions for fault code: No dosing, tank empty
(level < 11mm for plastic tank)
Possible reason: • Low AdBlue level
• Cables and the connector to the sensor
• Faulty sensor
Suitable action: 1 Fill tank with AdBlue
2 Check that the sensor is correctly installed
3 Check the cables and the connector to the sensor
4 Check the sensor
5 Check Vodia logparameter, Aftertreatment reagent level
Measurements: Checking the aftertreatment reagent tank temperature and level
sensor page 122

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Circuit description
The sensor is combined for temperature and level
measurement inside the AdBlue tank. The level sen-
sor delivers a voltage output on pin 2 0,5-4,5V from
48-320mm (20/50L tank volume).Tolerance float
decending ± 5mm. The temperature (°C) delivers a
resistance output on pin 3.

Sensor UDS2 Signal type

Pin 1 30 Supply voltage +5V
Pin 2 18 Output 0,5-4,5V (Level)
Pin 3 29 Output resistance
(temp.)
Pin 4 19 Batt negative (GND)

Component location
The combinated temperature and level sensor is
located inide the AdBlue tank with the connections
visible at the top.

P0011695 3

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MID 128, PPID 385 After-treatment

Reagent Control Unit Voltage

MID 128: Engine control unit

FMI 3 – Voltage above normal or shorted high

Fault code explanation: Voltage above normal (to high)
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: SCR-system does not start-up
Conditions for fault code: > 32 V
Possible reason: • Supply voltage UBatt positive
• Faulty UDS2
Suitable action: 1 Check supply voltage (UBatt positive) on UDS2 pin 3 and pin 4
2 Change pump unit (UDS2 integrated)

FMI 4 – Voltage below normal or shorted to lower voltage

Fault code explanation: Voltage below normal (to low)
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: SCR-system does not start-up
Conditions for fault code: < 16 V
Possible reason: • Supply voltage UBatt
• Fuse
• Cables and the connectors
• Faulty UDS2
Suitable action: 1 Check supply voltage (UBatt positive) on UDS2 pin 3 and pin 4
2 Check fuse EATS
3 Check the cables and the connector to the UDS2

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FMI 12 – Faulty device or component

Fault code explanation: Internal voltage supply failure
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: SCR-system does not start-up
Conditions for fault code: Internal supply error UDS2
Possible reason: • Internal supply error UDS2
Suitable action: 1 Check the cables and the connector to the UDS2
2 Change pump unit (Integrated UDS2)

FMI 14 – Special instructions

Fault code explanation: Internal voltage supply critical failure
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: SCR-system does not start-up
Conditions for fault code: Internal supply critical error UDS2
Possible reason: • Internal supply critical error UDS2
Suitable action: 1 Check the cables and the connector to the UDS2
2 Change pump unit (Integrated UDS2)

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Circuit description
The aftertreatment regent control unit (MID 233,
UDS2) is connected to the engine mounted EMS via
CAN-bus J1939. All faultcodes is sent via the EMS
and therefore the shown source is the EMS
(MID128). The AdBlue amount that is beeing injected
is controlled by the EMS. The UDS2 is integrated in
the pump unit and can not be changed separately. It
is programmed with the Volvo Penta chassis id.

UDS2 Signal type

Pin 14 (splice3) Batt negative (GND)
Pin 15 (splice3) Batt negative (GND)
Pin 3 (splice4) UBatt positive
Pin 4 (splice4) UBatt positive

Component location
The aftertreatment reagent control unit
(MID233,UDS2) is integrated in the pump unit and is
located in the back of the pump unit.

1 UDS2 unit

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MID 128, PSID 7 Throttle Actuator

MID 128: Engine control unit

FMI 3 – Voltage above normal or shorted high

Fault code explanation: Short circuit to positive side.
Fault indication: 1 DCU (Display Control Unit)
Engine warning in DCU display.
2 DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: > 4.84 V (DC)
Possible reason: • Short circuit to positive side.
• Faulty harness
• Faulty throttle
Suitable action: 1 Check that the throttle is correctly installed and clean.
2 Check the cables and the connectors between the throttle and the
EMS.
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

FMI 4 – Voltage below normal or shorted to lower voltage

Fault code explanation: Short circuit to negative side
Fault indication: 1 DCU (Display Control Unit)
Engine warning in DCU display.
2 DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: < 0.56 V (ADC)
Possible reason: • Short circuit to negative side
• Faulty harness
• Faulty throttle
Suitable action: 1 Check that the throttle is correctly installed and clean.
2 Check the cables and the connectors between the throttle and the
EMS.
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

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FMI 5 – Current below normal or open circuit

Fault code explanation: Open Circuit
Fault indication: 1 DCU (Display Control Unit)
Engine warning in DCU display.
2 DU (Display Unit)
Engine warning in DU display.
Symptom: Throttle set in default position (fully open).
Conditions for fault code: Information missing
Possible reason: • Open Circuit
• Faulty harness
• Faulty throttle
Suitable action: 1 Check that the throttle is correctly installed and clean.
2 Check the cables and the connectors between the throttle and the
EMS.
Measurements: • Checking the throttle motor page 114
• Checking the throttle mechanical position page 114

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Circuit description
The throttle position sensor is a Hall effect generator.
The working range is between 0,5V to 4,4V and
starts with a closed throttle up to fully open. The out-
put from the sensor is linear (output voltage / % open
throttle). Position accuracy is +-0,1 degree.The
engine control unit uses the sensor signal to calcu-
late the throttle position. When the throttle gets the
order to turn, the EMS sets +24V on pin EB1 (open)
or pin EB5 (close). Each time by key on, the throttle
run a calibration cycle for checking the valve position.

Sensor UDS 2 Signal type

Pin 1 EB5 Motor voltage 1
Pin 2 EB17(splice7) Supply voltage 5V
(throttle position)
Pin 3 EB18(splice8) Batt negative (Gnd
throttle position)
Pin 4 EB1 Motor voltage 2
Pin 5 EB24 Output throttle position
(H-bridge)

Component location
The throttle is located on the engines air intake.

CAUTION!
Pinch hazard. Keep fingers clear.

P0014415

P0010764

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MID 128, PSID 46 NOx monitoring

failure

MID 128: Engine control unit

FMI 0 – Data valid but above normal operational range

Fault code explanation: Inducement level 3, 4, 5.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: • Engine derate.
• Severe inducement.
Conditions for fault code: For complete description, see Wiring Diagram SCR system UDS2 TAD
56x, 76x, 136x, 166x VE and Wiring Diagram SCR-system UDS2 TWG
TWD 1663 GE in chapter Electrical Power Supply, Lightning, Instruments,
Software page 140
Warning / pre-trigger derate (inducement level 3, 4, 5).
Possible reason: For complete description, see Wiring Diagram SCR system UDS2 TAD
56x, 76x, 136x, 166x VE and Wiring Diagram SCR-system UDS2 TWG
TWD 1663 GE in chapter Electrical Power Supply, Lightning, Instruments,
Software page 140.
Suitable action: For complete description, see Wiring Diagram SCR system UDS2 TAD
56x, 76x, 136x, 166x VE and Wiring Diagram SCR-system UDS2 TWG
TWD 1663 GEin chapter Electrical Power Supply, Lightning, Instruments,
Software page 140.

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FMI 15 – Data valid but above normal operational range

Fault code explanation: Inducement level 1, 2.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
(Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display.
(Derate red light)
Symptom: • Engine warning.
• Pre-trigger engine derate.
Conditions for fault code: For complete description, see Wiring Diagram SCR system UDS2 TAD
56x, 76x, 136x, 166x VE and Wiring Diagram SCR-system UDS2 TWG
TWD 1663 GE in chapter Electrical Power Supply, Lightning, Instruments,
Software page 140.
Warning / pre-trigger derate (inducement level 1, 2).
Possible reason: For complete description, see Wiring Diagram SCR system UDS2 TAD
56x, 76x, 136x, 166x VE and Wiring Diagram SCR-system UDS2 TWG
TWD 1663 GE in chapter Electrical Power Supply, Lightning, Instruments,
Software page 140.
Suitable action: For complete description, see Wiring Diagram SCR system UDS2 TAD
56x, 76x, 136x, 166x VE and Wiring Diagram SCR-system UDS2 TWG
TWD 1663 GE in chapter Electrical Power Supply, Lightning, Instruments,
Software page 140.

Circuit description
Function together with PSID 90.
This faultcode funktion is for evaluating the SCR sys-
tem status.
1 The status of NOx conversion, between actual
injected amount of AdBlue compared with the
actual level of emissions. Function AdBlue quality.
2 The tank level status, Function AdBlue tank level.
3 SCR system controlling, Function SCR tampering.

NOTICE! For complete description, see Wiring dia-

gram TWD 1663 GE / TWG 1663 and PIN explana-
tion EMS2.2, TWD 1663 GE / TWG 1663 GE in
chapter Electrical Power Supply, Lightning, Instru-
ments, Software page 140.

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MID 128, PSID 77 ACM control unit

EEPROM

MID 128: Engine control unit

FMI 3 – Voltage above normal or shorted high

Fault code explanation: ACM control unit, internal voltage supply high
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: Information missing
Possible reason: • Supply voltage Ubatt positive high
• Faulty UDS2
Suitable action: 1 Check supply voltage (UBatt positive) on UDS2 pin 3 and pin 4
2 Change pump unit (UDS2 integrated)

FMI 4 – Voltage below normal or shorted to lower voltage

Fault code explanation: ACM control unit, internal voltage supply low
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: Information missing
Possible reason: • Supply voltage UBatt low
• Faulty UDS2
• Fuse EATS
Suitable action: 1 Check supply voltage (UBatt positive) on UDS2 pin 3 and pin 4
2 Check fuse EATS
3 Check the cables and the connector to the UDS2
4 Change pump unit (UDS2 integrated)

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FMI 12 – Faulty device or component

Fault code explanation: Checksum communication
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: Checksum, communication or write
Possible reason: • Supply voltage UBatt
• Faulty UDS2
• Fuse EATS
Suitable action: 1 Check supply voltage (UBatt positive) on UDS2 pin 3 and pin 4
2 Check fuse EATS
3 Check the cables and the connector to the UDS2
4 Change pump unit (UDS2 integrated)

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Circuit description
The aftertreatment reagent control unit (MID 233,
UDS2) is connected to the engine mounted EMS via
CAN-bus J1939. All faultcodes is sent via the EMS
and therefore the shown source is the EMS
(MID128). The AdBlue amount that is beeing injected
is controlled by the EMS. The UDS2 is integrated in
the pump unit and can not be changed separately. It
is programmed with the Volvo Penta chassis id.

UDS2 Signal type

Pin 14 (splice3) Batt negative (GND)
Pin 15 (splice3) Batt negative (GND)
Pin 3 (splice4) UBatt positive
Pin 4 (splice 4) UBatt positive

Component location
The aftertreatment reagent control unit
(MID233,UDS2) is integrated in the pump unit and is
located in the back of the pump unit.

1 UDS2 unit

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MID 128, PSID 85 After-treatment

Reagent Dosing Sys ECU Main
Relay

MID 128: Engine control unit

FMI 6 – Current above normal or grounded circuit

Fault code explanation: Shut off too late
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: The UDS2 has not shut down after 92 sec since ignition off (Main relay)
Possible reason: • Faulty UDS2
• Faulty DCU
Suitable action: 1 Check DCU
2 Change pump unit (UDS2 integrated)

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Circuit description
Function used to protect battery from beeing drained.
Normal shut off time is 5sec. The aftertreatment
reagent control unit (MID 233, UDS2) is connected to
the engine mounted EMS via CAN-bus J1939. All
faultcodes is sent via the EMS and therefore the
shown source is the EMS (MID128). The AdBlue
amount that is beeing injected is controlled by the
EMS. The UDS2 is integrated in the pump unit and
can not be changed separately. It is programmed
with the Volvo Penta chassis id.

UDS2 Signal type

Pin 14 (splice3) Batt negative (GND)
Pin 15 (splice3) Batt negative (GND)
Pin 3 (splice4) UBatt positive
Pin 4 (splice 4) UBatt positive

Component location
The aftertreatment reagent control unit
(MID233,UDS2) is integrated in the pump unit and is
located in the back of the pump unit.

1 UDS2 unit

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MID 128, PSID 87 After-treatment

Reagent Pump Motor Speed

MID 128: Engine control unit

FMI 0 – Data valid but above normal operational range

Fault code explanation: Over speed pump motor
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: No AdBlue dosing
Conditions for fault code: Motor speed > 6000 rpm
Possible reason: • Faulty AdBlue pump
• Faulty harness / Connectors pump unit
Suitable action: 1 Check the cables and the connectors inside the pump unit on the
pump board.
2 Change pump unit (pump integrated)

FMI 1 – Data valid but below operational range

Fault code explanation: Under speed pump motor
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: No AdBlue dosing
Conditions for fault code: Motor speed < 600 rpm
Possible reason: • Faulty AdBlue pump
• Faulty harness / Connectors pump unit
Suitable action: 1 Check the cables and the connectors inside the pump unit on the
pump board.
2 Change pump unit (pump integrated)

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FMI 10 – Abnormally large variations

Fault code explanation: No signal from pump
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: No AdBlue dosing
Conditions for fault code: No signal from pump
Possible reason: 1 Faulty AdBlue pump
2 Faulty harness / Connectors pump unit
Suitable action: 1 Check the cables and the connectors inside the pump unit on the
pump board.
2 Change pump unit (pump integrated)

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Circuit description
The Aftertreatment reagent pump is intergrated in the
pump unit and not possible to change as a separate
part. It pumps up the system pressure to 5 bar
(500kPa) and also drain the system by key off
together with the direction valve function. The pump
is supplied internaly from the UDS2. The electrical
pump is a 24V DC membrane pump with a power
consumption of 3,5A when working.

Pump UDS2 Signal type

Internal pump unit

Component location
The Aftertreatment reagent pump motor is inter-
graded in the pump unit and located at the left bot-
tom side.

NOTICE! When opening the cover of the pump unit,

the pump unit must be checked so it is completely
sealed when service work is finished. Use pressure
test pump 88890104 and pressure test nipple
88890102.

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MID 128, PSID 89 After-treatment

Reagent Dosing Valve

MID 128: Engine control unit

FMI 3 – Voltage above normal or shorted high

Fault code explanation: Short circuit to positive side.
Fault indication: 1 DCU (Display Control Unit)
Engine warning in DCU display.
2 DU (Display Unit)
Engine warning in DU display.
Symptom: No AdBlue dosing
Conditions for fault code: < 0,15 A
Possible reason: • Short circuited sensor supply cable.
• Faulty injector.
Suitable action: 1 Check all the cables and connectors between the sensor and the
UDS2.
2 Check the dosing valve.
Measurements: • Checking the aftertreatment reagent dosing valve page 121

FMI 4 – Voltage below normal or shorted to lower voltage

Fault code explanation: Short circuit to negative side
Fault indication: 1 DCU (Display Control Unit)
Engine warning in DCU display.
2 DU (Display Unit)
Engine warning in DU display.
Symptom: No AdBlue dosing
Conditions for fault code: > 4,6 A
Possible reason: • Short circuited sensor supply cable.
• Faulty injector.
Suitable action: 1 Check all the cables and connectors between the sensor and the
UDS2.
2 Check the dosing valve.
Measurements: • Checking the aftertreatment reagent dosing valve page 121

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FMI 5 – Current below normal or open circuit

Fault code explanation: Open Circuit
Fault indication: 1 DCU (Display Control Unit)
Engine warning in DCU display.
2 DU (Display Unit)
Engine warning in DU display.
Symptom: None
Conditions for fault code: > 4,6 A or < 0,15 A
Possible reason: • Open circuited sensor supply cables.
• Faulty injector.
Suitable action: 1 Check all the cables and connectors between the sensor and the
UDS2.
2 Check the dosing valve.
Measurements: • Checking the aftertreatment reagent dosing valve page 121

FMI 7 – Mechanical system not responding properly

Fault code explanation: Wrong mechanical answer
Fault indication: 1 DCU (Display Control Unit)
Engine warning in DCU display.
2 DU (Display Unit)
Engine warning in DU display.
Symptom: None
Conditions for fault code: Information missing / Wrong mechanical answer
Possible reason: Dosing valve
Suitable action: 1 Check all the cables and connectors between the sensor and the
UDS2.
2 Check the dosing valve.
Measurements: • Checking the aftertreatment reagent dosing valve page 121

FMI 10 – Abnormally large variations

Fault code explanation: Valve can not move
Fault indication: 1 DCU (Display Control Unit)
Engine warning in DCU display.
2 DU (Display Unit)
Engine warning in DU display.
Symptom: None
Conditions for fault code: Information missing
Possible reason: • Valve stucked
• Abnormal variations
Suitable action: 1 Check all the cables and connectors between the sensor and the
UDS2.
2 Check the dosing valve.
Measurements: • Checking the aftertreatment reagent dosing valve page 121

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FMI 14 – Special instructions

Fault code explanation: Frozen too many times
Fault indication: 1 DCU (Display Control Unit)
No warning light in display
2 DU (Display Unit)
No warning light in display
Symptom: None
Conditions for fault code: • FCC1 (Frozen Cycle Counter 1), Number of cold starts with drained
system.
• FCC2 (Frozen Cycle Counter 2), Number of cold starts with
undrained system.

If counters reach 1000 times it activates FMI14

Possible reason: • Valve stucked
• Abnormal variations
Suitable action: 1 Clear faultcode with reset of the counters, use VODIA
2 Change dosing valve also run VODIA dosing test
Measurements: • Checking the aftertreatment reagent dosing valve page 121

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Circuit description
When a number of conditions is fulfilled, e.g. when
the AdBlue system pressure is high enough, when
the exhaust temperature is hot enough, etc. the EMS
(MID128) sends a request to the UDS2 (MID233)
that opens the dosing valve. AdBlue is then injected
into the SCR-catalyst inlet pipe. The valve is mag-
netic, PWM (Puls Width Modulation) controlled. The
valve is voltage supplied by the UDS2.

Sensor UDS2 Signal type

Pin 1 Pin12 Supply voltage +5V
Pin 2 Pin11 Batt negative (GND)
P0011672

Component location
The aftertreatment reagent dosing valve is located on
the exhaust inlet of the muffler

p0013248

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MID 128, PSID 90 After-treatment

Reagent Dosing System

MID 128: Engine control unit

FMI 1 – Data valid but below operational range

Fault code explanation: SCR system dosing failure.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display. (Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display. (Derate red light)
Symptom: Engine derate, see derate schedule.
Conditions for fault code: Too low AdBlue concentration / Too low AdBlue dosing.
Possible reason: • AdBlue out of specification (ISO 22241).
• Low AdBlue concentration.
• Too low AdBlue dosing.
Suitable action: 1 Check AdBlue quality.
2 Run VODIA dosing test.

FMI 14 – Special instructions

Fault code explanation: SCR system Major functional failure.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display. (Derate red light and buzzer)
• DU (Display Unit)
Engine warning in DU display. (Derate red light)
Symptom: Engine derate, see derate schedule.
Conditions for fault code: • SCR catalyst removed.
• AdBlue out of specification.
• Clogged dosing system.
Possible reason: • Poor AdBlue quality (Diluted AdBlue)
• Poor AdBlue quality (blocked or clogged urea delivery line / faulty
dosing valve or nozzle / UDS2 dosing control / SCR catalyst dam-
aged)
Suitable action: 1 Check AdBlue quality.
2 Run VODIA dosing test.

Circuit description
Function together with PSID 46.
This faultcode function is for evaluating the SCR sys-
tem status.
1 The status of NOX conversion, between actual
injected amount of AdBlue compared with the
actual level of emissions. Function AdBlue quality.
2 The tank level status, Function AdBlue tank level.
3 SCR system controlling, Function SCR tampering.

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MID 128, PSID 91 After-treatment

Reagent Consumption

MID 128: Engine control unit

FMI 0 – Data valid but above normal operational range

Fault code explanation: Tank level change too much
Fault indication: • DCU (Display Control Unit)
No warning light in display
• DU (Display Unit)
No warning light in display
Symptom: N/A
Conditions for fault code: AdBlue consumption and level change does not correlate (to high AdBlue
consumption)
Possible reason: • System leakage
• Wrong specification on dosing module
• Wrong specification on pump unit
• Faulty sensor
Suitable action: 1 Check system for leakage
2 Check that the sensor is correctly installed and clean.
3 Check injector and pump version.
4 Check the dosing valve, run Vodia dosing test.
5 Check level sensor.
Measurements: • Checking the aftertreatment reagent dosing valve page 121

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FMI 1 – Data valid but below operational range

Fault code explanation: Tank level change too little
Fault indication: • DCU (Display Control Unit)
No warning light in display
• DU (Display Unit)
No warning light in display
Symptom: N/A
Conditions for fault code: AdBlue consumption and level change does not correlate (to low AdBlue
consumption)
Possible reason: • Clogged system
• Wrong specification on dosing module
• Wrong specification on pump unit
• Faulty sensor (level stuck)
• AdBlue dosing module (nozzle / dosing valve)
Suitable action: 1 Check that the sensor is correctly installed and clean.
2 Check injector and pump version.
3 Check the dosing valve, run Vodia dosing test.
4 Check level sensor.
Measurements: • Checking the aftertreatment reagent dosing valve page 121

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Circuit description
The sensor is combined for temperature and level
measurement inside the AdBlue tank. The level sen-
sor delivers an voltage output on pin 2 0,5-4,5V from
48-320mm (20/50L tank volume).Tolerance float
decending ± 5mm. The temperature (°C) delivers a
resistance output on pin 3.

Sensor UDS2 Signal type

Pin 1 30 Supply voltage +5V
Pin 2 18 Output 0-4,5V (Level)
Pin 3 29 Output resistance
(temp.)
Pin 4 19 Batt negative (GND)

Component location
The combined temperature and level sensor is
located inide the AdBlue tank with the connections
visible at the top.

P0011695 3

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MID 128, PSID 105 After-treatment

Reagent Direction Valve

MID 128: Engine control unit

FMI 3 – Voltage above normal or shorted high

Fault code explanation: Short circuit to positive side.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: Information missing/Short circuit to positive side.
Possible reason: • Directionvalve
• Harness internal pump unit
• UDS2
Suitable action: 1 Check all the cables and connectors between the valve and the
UDS2.
2 Check the dosing valve.
Measurements: • Checking the aftertreatment reagent dosing valve page 121

FMI 4 – Voltage below normal or shorted to lower voltage

Fault code explanation: Short circuit to negative side
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: Information missing/Short circuit to negative side
Possible reason: • Directionvalve
• Harness internal pump unit
• UDS2
Suitable action: 1 Check all the cables and connectors between the valve and the
UDS2.
2 Check the dosing valve.
Measurements: • Checking the aftertreatment reagent dosing valve page 121

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FMI 5 – Current below normal or open circuit

Fault code explanation: Open Circuit
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: Information missing/Open Circuit
Possible reason: • Directionvalve
• Harness internal pump unit
• UDS2
Suitable action: 1 Check all the cables and connectors between the valve and the
UDS2.
2 Check the dosing valve.
Measurements: • Checking the aftertreatment reagent dosing valve page 121

FMI 7 – Mechanical system not responding properly

Fault code explanation: Mechanical failure
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: Information missing/Wrong mechanical answer
Possible reason: Directionvalve
Suitable action: 1 Check all the cables and connectors between the valve and the
UDS2.
2 Check the direction valve.
Measurements: • Checking the aftertreatment direction valve page 124

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Circuit description
The aftertreatment reagent direction valve is control-
led by the UDS2 (MID233). In normal operation the
valve position is set for feeding the dosing valve with
AdBlue pressure, also when not dosing for cooling
down the dosing module. If ignition off is activated (0
voltage on pin 24, UDS2) the UDS2 carry out "after-
run" to drain the system. The direction valve change
the valve position so the system can drain back to
the tank.

Valve UDS2 Signal type

Pin 1 Supply voltage +24V
Pin 2 Batt negative (GND)

Component location
The aftertreatment reagent direction valve is located
on the upper left side inside the pump unit.

NOTICE! When opening the cover of the pump unit,

the pump unit must be checked so it is completely
sealed when service work is finished. Use pressure
test pump 88890104 and pressure test nipple
88890102.

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MID 128, PSID 201 Data link,

MID144

MID 128: Engine control unit

FMI 9 – Abnormal update rate

Fault code explanation: No contact with the VECU/DCU
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: Message missing on bus
Possible reason: • The CAN-bus J1939 is down
• EATS Fuse
• Faulty harness
Suitable action: 1 Check EATS fuse
2 Check the cables and the connectors between the EMS and the
UDS2.

Circuit description
The aftertreatment reagent control unit (MID 233,
UDS2) is connected to the engine mounted EMS via
CAN-bus J1939. All faultcodes is sent via the EMS
and therefore the shown source is the EMS
(MID128). The AdBlue amount that is beeing injected
is controlled by the EMS. The UDS2 is integrated in
the pump unit and can not be changed separately. It
is programmed with the Volvo Penta chassis id.

Connec- UDS2 Signal type

tor
Pin 1 EA7(splice2) CAN L
Pin 2 EA7(splice2) CAN H

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MID 128, PSID 229 SAE J1939 Data

Link, SubNet 1, MID 233

MID 128: Engine control unit

FMI 9 – Abnormal update rate

Fault code explanation: CAN bus time out
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: No AdBlue dosing
Conditions for fault code: CAN frames gone >5s
Possible reason: • The CAN-bus J1939 is down
• EATS Fuse
• Faulty harness
Suitable action: 1 Check EATS fuse
2 Check the cables and the connectors between the EMS and the
UDS2.

FMI 11 – Unidentifiable error

Fault code explanation: Root cause not known
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: No AdBlue dosing
Conditions for fault code: UDS is not in normal operation mode even though all conditions are ok.
Possible reason: UDS2
Suitable action: 1 Check EATS fuse
2 Check the cables and the connectors between the EMS and the
UDS2.
3 Change UDS2 (pump unit)

Circuit description
The aftertreatment reagent control unit (MID 233,
UDS2) is connected to the engine mounted EMS via
CAN-bus J1939. All faultcodes is sent via the EMS
and therefore the shown source is the EMS
(MID128). The AdBlue amount that is beeing injected
is controlled by the EMS. The UDS2 is integrated in
the pump unit and can not be changed separately. It
is programmed with the Volvo Penta chassis id.

Connec- UDS2 Signal type

tor
Pin 1 EA7 (splice2) CAN L
Pin 2 EA7 (splice2) CAN H

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MID 128, PSID 232 SAE J1939-1

SubNet 1, Control link

MID 128: Engine control unit

FMI 2 – Abnormal update rate

Fault code explanation: • Short circuit to positive side.
• Short circuit to negative side
• Open circuit on either side
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: • Short circuit to positive side.
• Short circuit to negative side
• Open circuit on either side (200ms)
Possible reason: • Supply voltage
• Fuse EATS
• Harness between engine EATS
Suitable action: 1 Check fuse EATS
2 Check the cables and the connectors between engine and EATS

Circuit description
The aftertreatment reagent control unit (MID 233,
UDS2) is connected to the engine mounted EMS via
CAN-bus J1939. All faultcodes is sent via the EMS
and therefore the shown source is the EMS
(MID128). The AdBlue amount that is beeing injected
is controlled by the EMS. The UDS2 is integrated in
the pump unit and can not be changed separately. It
is programmed with the Volvo Penta chassis id.

Connec- UDS2 Signal type

tor
Pin 1 EA7(splice2) CAN L
Pin 2 EA7(splice2) CAN H

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MID 128, SID 232 5 V supply

MID 128: Engine control unit

FMI 3 – Data erratic, intermittent or incorrect

Fault code explanation: Voltage above range
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: > 5,505 V, 5 sec
Possible reason: • Faulty harness
• Faulty sensor
• PID26 / PID102 / PID132 / PID164 / PID411 / PID354
Suitable action: 1 Check that the sensor is correctly installed and clean.
2 Check the cables and the connectors between the sensor and the
EMS / UDS2.

FMI 4 – Faulty device or component

Fault code explanation: Voltage below range
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: < 4,495 V, 5 sec
Possible reason: • Check the fuse
• Faulty sensor
• Faulty harness
• PID26 / PID102 / PID132 / PID164 / PID411 / PID354
Suitable action: 1 Check the engine fuse and the EATS fuse
2 Check the cables and the connectors between the sensor and the
EMS / UDS2.
3 Check that the sensor is correctly installed and clean.

Circuit description
There are two sensors supplied from the UDS2 with
+5V DC, exhaust temperature sensor and level / tem-
perature sensor. The SCR specific sensor for humid-
ity/temperature on the D13/D16 base engines is sup-
plied from the EMS together with the sensors, oil
level/temperature, boost pressure/temperature and
visco fan speed. This means that a supply failure can
be caused by several sources.

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MID 128, SID 253 Calibration

memory EEPROM

MID 128: Engine control unit

FMI 2 – Data erratic, intermittent or incorrect

Fault code explanation: Checksum error.
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: 100ms / checksum error
Possible reason: Control unit
Suitable action: 1 Check the cables and the connectors between the EMS and the
UDS2.

FMI 12 – Faulty device or component

Fault code explanation: Checksum error vendor
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: 100ms / checksum error vendor
Possible reason: Control unit
Suitable action: 1 Check the cables and the connectors between the EMS and the
UDS2.

FMI 14 – Special instructions

Fault code explanation: Checksum error on E2
Fault indication: • DCU (Display Control Unit)
Engine warning in DCU display.
• DU (Display Unit)
Engine warning in DU display.
Symptom: N/A
Conditions for fault code: 100ms / checksum error on E2
Possible reason: Control unit
Suitable action: 1 Check the cables and the connectors between the EMS and the
UDS2.

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Circuit description
The aftertreatment reagent control unit (MID 233,
UDS2) is connected to the engine mounted EMS via
CAN-bus J1939. All faultcodes is sent via the EMS
and therefore the shown source is the EMS
(MID128). The AdBlue amount that is beeing injected
is controlled by the EMS. The UDS2 is integrated in
the pump unit and can not be changed separately. It
is programmed with the Volvo Penta chassis id.

1 UDS2 unit

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 30-2 Fault Tracing

Measurements
Measurements
Tools:
9990014 Break-out cable
9998699 Break-out box
88890052 Break-out cable
88890074 Multimeter

p0005125

P0013449
P0008793

Connection of 9990014 Break-out cable or

88890052 Break-out cable
1 Cut the current with the main switch.
2 Disconnect the EMS or UDS2.
3 Connect 990014 to the EMS, also connect the
engine cable harness to 990014 or connect
88890052 to the UDS2 (use connector, code7),
also connect the SCR cable harness to
8890052.
4 Connect 9998699 to 990014 (EMS) or 9998699
to 88890052 (UDS2).
5 Turn the main switch on.
6 Use 88890074 to perform voltage measure-
ments by using the measurement points on
9998699.

NOTICE! If resistance measurements are to be

performed the main switch must be turned off
and the EMS / UDS2 must be disconnected.

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Interpretation of measurement table

Column 1 "Component" shows different components that can be measured.
Column 2 "EMS / UDS #" shows the components pin numbers on the EMS or UDS2.
Column 3 "Measurebox #" shows what measurement points on 9998699 that equals the
pin numbers on the EMS or UDS2.
Column 4 "Sensor pin #" shows what pin numbers on the component equals the meas-
urement points on 9998699.
Column 5 "Signal type" shows what kind of signal there is between the component and
the EMS / UDS2.
Column 6 "Ignition on" shows the expected voltage drop inbetween the component
pins at ignition on.
Column 7 "Engine running" shows the expected voltage drop inbetween the component
pin when engine is running.
Column 8 "Note" shows information about the component.

Component Con- Meas. Sensor Signal type Ignition on Engine Note

trol # box # pin # run-
EMS/U ning
DS
Air throttle EB1 1 4 Motor voltage 2 - - Coil resistance 1-4 =
(EMS) 6,5 (+/- 1 at 20° C
EB5 5 1 Motor voltage 1 - - -
EB17 17 2 (+) Supply 2-3 = 5V - -
EB18 18 3 (-) GND 3-bat(-) = 0V - -
EB24 24 5 Output throttle pos 3-5 = 0-4,4V - U depended of valve
position, see table
Relative EA7 7 1 (+) Supply 3-bat(-) = 0V - -
Humidity EA11 11 3 (-) GND 1-3 = 5V - -
Air Tempera-
EA23 23 2 Output humidity 2-3 = 0,5-4,5V - -
ture (EMS)
EA43 43 4 Output temp 3-4 = 0-5V - U is depended of
the temp, see table
NOx sensor 5 5 1 CAN H J1939 - - -
(UDS2) 6 6 2 CAN L J1939 - - -
- - 3 (-) GND 3-bat(-) = 0V - -
(batt)
- - 4 (+) Supply 3-4 = 24V - -
(batt)
Aftertreat- - - 1 (+) Supply 1-2 = 5V - -
ment - - 2 (-) GND 2-bat(-) = 0V - -
Reagent
- - 3 Output pressure 2-3 = 0,7-2,9V - U depended of pres-
pressure
sure, see table
sensor
(UDS2)
Aftertreat- 18 18 2 Output level 2-4 = 0-4,55V - -
ment 19 19 4 (-) GND 4-bat(-) = 0V - -
Reagent tank
29 29 3 Output temp 3-4 = 0-5V - U is depended of
temp
the temp, see table
Tank Level
(UDS2) 30 30 1 (+) Supply 1-4 = 5V - -
Aftertreat- - - 1 (+) Supply 1-2 = 5V - -
ment - - 2 Output temp 1-2 = 0-5V - U is depended of
Regent filter the temp, see table
temp
- - - - - - -
(UDS2)

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Aftertreat- 17 17 2 Output temp 1-2 = 0-5V - U is depended of

ment the temp, see table
Exhaust 28 28 1 (+) Supply 1-2 = 5V - -
Temperature
- - - - - - -
(UDS2)
Aftertreat- 11 11 2 (-) GND 2-bat(-) = 0V - Coil resistance 1-2 =
ment 1,3 (+/- 1 at 20° C
Reagent dos- 12 12 1 (+) Supply 1-2 = 24V - -
ing
- - - - - - -
Valve
(UDS2)
Aftertreat- - - 1 (+) Supply 1-2 = 24V - Coil resistance 1-2 =
ment 17,8 (+/- 1 at 20° C
Reagent - - 2 (-) GND 2-bat(-) = 0 - -
direction
Valve
(UDS2)
Tank heat- 3 3 1 (+) Supply 1-2 = 24V - Coil resistance 1-2 =
ing valve 46,4 (+/- 1 at 20° C
(UDS2) 23 23 2 (-) GND 2-bat(-) = 0 - -

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Checking the throttle motor

Tools:
88890074 Multimeter
1 Cut the current with the main switch.
2 Remove the connector from the throttle. Check
that the throttle connector has no external dam-
age.
3 Use multimeter 88890074 for resistance meas-
urement.
4 Measure between pin 1 and pin 4 on the throttle
connector, an ohm value shall be shown, if not
the motor wires have an open circuit and throttle
must be replaced.
5 Measure between pin 1 and pin 3, an ohm value
shall not be shown, if a value is shown the
motor wires have a short circuit to ground and
the throttle must be replaced.
6 Measure between pin 4 and pin 3, an ohm value
shall not be shown, if a value is shown the
motor wires have a short circuit to ground and
the throttle must be replaced.

Checking the throttle mechanical

position
Tools:
88890074 Multimeter
1 Remove the complete throttle.
2 Check that the throttle has no external damage.
3 Push the air valve and feel that it can move
easy through the complete working area.
4 When the air valve is turned, release it and it
must move back by it’s own with the spring
force to the default position (fully open).

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Checking the combinated relative

humidity and temperature sensor
Tools:
9990014 Break-out cable
9998699 Break-out box
88890074 Multimeter
1 NOTICE! Cut the current with the main switch.
2 Connect the break-out cable (9990014) and
break-out box (9998699) to the EMS connector
A.
3 Switch on the current with the main switch
4 Check supply voltage output from the EMS to
the sensor. Between EA47(splice2) +5V, EA11
(splice1) Batt negative (GND).
5 Check temp. output voltage between EA11
(splice1) Batt negative (GND), EA43 output volt-
age temp. ca 3,28V (+22°C)
6 Check humidity output voltage (see table)
between EA11(splice1) Batt negative (GND),
EA23 output voltage humidity.
7 NOTICE! Cut the current with the main switch.
8 Remove the connector from the sensor and
remove the sensor. Check that the sensor has
no external damage and that no metal chips etc
are stuck on the sensor.
9 Measure temp. resistance (see table) between
pin 3 and pin 4, an ohm value shall be shown, if
a value is not shown the sensor must be
replaced.
10 Measure humidity resistance between pin 3 and
pin 2, an ohm value shall be shown, if a value is
not shown the sensor must be replaced.

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30-2 Fault Tracing

Voltage Output (mV) "zero life"

RH % Minimum Nominal Maximum
1 903 950 996
10 1178 1240 1302
15 1255 1390 1525
20 1424 1540 1656
25 1587 1685 1783
30 1739 1825 1911
35 1882 1950 2038
40 2012 2090 2168
45 2142 2220 2298
50 2272 2350 2428
55 2402 2480 2558
60 2527 2605 2663
65 2652 2730 2808
70 2782 2660 2938
75 2912 2990 3068
80 3031 3125 3219
85 3120 3250 3380
90 3202 3370 3539
95 3344 3520 3696
99 3430 3610 3791

Temp Output (Ohm) "zero life"

ºC Minimum Nominal Maximum
-40 181215 188500 196059
-30 107625 111364 115222
-20 65851 67801 69803
-10 41422 42450 43499
0 26736 27276 27829
10 17674 17958 18244
20 11947 12091 12235
30 8214 8313 8411
40 5738 5827 5918
50 4082 4160 4239
60 2954 3020 3067
70 2172 2228 2264
80 1621 1667 1714
90 1227 1255 1305

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Checking the NOx-sensor

Tools:
885675 Break-out cable
9998699 Break-out box
88890074 Multimeter
88899052 Break-out cable

Checking supply voltage

1 NOTICE! Cut the current with the main switch.
2 Remove the connector from the harness to the
sensor.
3 Connect the break-out cable (88899052) and
break-out box (9998699) to the UDS2 connec-
tor.
4 Switch on the current with the main switch
5 Check supply voltage output from the UDS2 to
the NOx-sensor. Between pin 3(splice4) +24V
and pin 15(splice3) Batt negative (GND).
6 NOTICE! Cut the current with the main switch.
7 Connect the break-out cable (885675) to the
sensor. Do not connect the other end of the
adapter cable.
8 Switch on the current with the main switch
9 Check supply voltage output from the sensor
connector (harness) between pin 3 +24V, pin 4
Batt negative (GND).

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Checking the aftertreatment

reagent pressure sensor
Tools:
885675 Break-out cable
88890074 Multimeter

Checking supply voltage and pressure output voltage

1 NOTICE! Cut the current with the main switch.
2 Remove the connector from the sensor and
remove the sensor. Check that the sensor has
no external damage and that no metal chips etc
are stuck on the sensor.
3 Connect the break-out cable (885675) between
sensor connector and pump unit harness.
4 Switch on the current with the main switch
5 Check supply voltage to the sensor between pin
1, supply voltage 5 V & pin 2, batt negative
(GND).
6 Check output voltage (pressure value) from the
sensor between pin 2, batt negative (GND). &
pin 3, voltage output (approximately value by
ambient pressure 0,7 V - 2,9 V)
7 Disconnect the sensor and check supply voltage
from UDS2 by measuring between pin 1 and pin
2 using break-out cable 885675.

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Checking the heaters (not electric

heated hoses)

Tools:
88890074 Multimeter

NOTICE! SPN 4356 Backflow heater (internal UDS2)

is not possible to check.

1 NOTICE! Cut the current with the main switch.

2 Remove the connector from each heater.
3 Measure the resistance between pin 1 and pin
2, an ohm value shall be shown, if a value is not
shown the sensor must be replaced.

SPN 4355 Filter heater filter top (internal UDS2) Filter heater filter top (internal UDS2):
Value ca 6 Ω at 22°C,

Filter heater bottom (external)

Value ca 50 Ω at 22°C,

SPN 4356 Backflow heater (internal UDS2)

P0010782
SPN 2061 Filter heater bottom (external)

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Checking the aftertreatment

reagent filter temperature sensor
Tools:
885675 Break-out cable
88890074 Multimeter

Checking supply voltage, temperature voltage output

and resistive
1 NOTICE! Cut the current with the main switch.
2 Connect the break-out cable (885675) to the
sensor connector
3 Check supply voltage to the sensor between pin
1, supply voltage 5 V & pin 2, batt negative
(GND).
4 NOTICE! Cut the current with the main switch.
5 Connect the break-out cable (885675) between
sensor and UDS2 harness.
6 Switch on the current with the main switch
7 Check output voltage (temperature) from the
sensor between pin 2, batt negative (GND). &
pin 1, voltage output
8 NOTICE! Cut the current with the main switch.
9 Check on the sensor the temperature resestive
between pin 2 and pin 1.
R at 22°C ca 2,5 kΩ = ca 3,2V

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Checking the aftertreatment

reagent dosing valve
Tools:
88890074 Multimeter
885675 Break-out cable

Checking supply voltage and valve resistance

1 NOTICE! Cut the current with the main switch.
2 Remove the connector from the sensor and
remove the sensor. Check that the sensor has
no external damage and that no metal chips etc
are stuck on the sensor.
3 Connect the break-out cable (885675) between
dosing module and SCR harness.
4 Switch on the current with the main switch
5 Check supply voltage to the dosing module
between pin 1, supply voltage 5 V & pin 2, batt
negative (GND). (when pulsing)
6 NOTICE! Cut the current with the main switch.
7 Disconnect the break-out cable (885675) from
theSCR harness, keep the dosing module con-
nector.
8 Check on the sensor the dosing valve resistive
between pin 1 and pin 2, ex. 1,3Ω

A A
A + A = OK

B + B = OK

A + A = OK
2
2

B + B = OK
B B
p0013246

Pump unit and injector versions

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Checking the aftertreatment

reagent tank temperature and level
sensor
Tools:
88890074 Multimeter
885675 Break-out cable

Checking supply voltage, level output voltage and

temperature voltage output
1 NOTICE! Cut the current with the main switch.
2 Connect the break-out cable (885675) between
sensor connector and SCR harness.
3 Switch on the current with the main switch
4 Check supply voltage to the sensor between pin
1, supply voltage 5 V & pin 4, batt negative
(GND).
5 Check output voltage (level value) from the sen-
sor between pin 4, batt negative (GND). & pin 2,
voltage output (see output tables).
6 Check output voltage (temperature) from the
sensor between pin 4, batt negative (GND). &
pin 3, voltage output (see output tables).
7 NOTICE! Cut the current with the main switch.
8 Disconnect the break-out cable (885675) from
theSCR harness, keep the sensor connector.
9 Check on the sensor temperature resistive
between pin 4, batt negative (GND) and pin. R
at 22°C ca 5,4kΩ

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Tank volume 20/50 L Tank volume 15 L

L = 401 L = 389
E = 52 mm E = 42 mm
RUA = 16 mm RUA = 16 mm
Output (Y) H (mm) Output (Y) H (mm)
4,55 >320 4,55 >304
4,33 320 4,28 304
4,08 304 4,02 288
3,85 288 3,77 272
3,62 272 3,51 256
3,40 256 3,26 240
3,16 240 3,00 224
2,94 224 2,75 208
2,73 208 2,51 192
2,49 192 2,28 176
2,26 176 2,05 160
2,04 160 1,83 144
1,82 144 1,62 128
1,59 128 1,40 112
1,37 112 1,18 96
1,15 96 0,95 80
0,90 80 0,71 64
0,71 64 0,50 48
0,50 48

NOTICE! Tolerance float decending ± 5mm

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Checking the aftertreatment

direction valve
Tools:
88890074 Multimeter
885675 Break-out cable

Checking supply voltage and valve resistance

1 NOTICE! Cut the current with the main switch.
2 Remove the connector from the valve. Check
that the valve has no external damage.
3 Connect the break-out cable (885675) between
valve connector and pump unit harness.
4 Switch on the current with the main switch
5 Make a "key off"(after-run starts) and check
supply voltage to the valve between pin 1, sup-
ply voltage 24 V & pin 2, batt negative (GND).
6 NOTICE! Cut the current with the main switch.
7 Disconnect the break-out cable (885675) from
theSCR harness, keep the valve connector.
8 Check on the sensor the dosing valve resistive
Valve position, flow direction back to tank between pin 1 and pin 2, ex. 18,4Ω

Valve position, flow direction to injector (default valve position)

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30-3 Bi-Fuel Engines

Technical Data
Knock sensor (bi-fuel)
Connector 2-pin
Type Piezo ceramic
Max. tightening torque 20 + 5 Nm (14.8 + 3.7 lbf. ft.)

CNG Throttle, natural gas to air inlet (bi-fuel)

Power supply 10-32 VDC, max. 2.5 A
Connector 12-pin
Type Bi-directional
Position control PMW
Position sensor type Hall effect sensor

Bi-fuel mode, system description

The EMS is controlling the activation / deactivation of
the bi-fuel mode.

Activation conditions for bi-fuel mode:

• 1000 rpm <= Engine speed <= 2100 rpm
• Indicated torque is above the On limit and not
below the Off limit.
On limit = 1350 Nm (996 lbf. ft.)
Off limit = 1150 Nm (848 lbf. ft.)
• Coolant temperature > 70 °C (158 °F)
When all activation conditions are fulfilled, the
engine ramps during seven seconds from 100
% diesel operation to 100 % bi-fuel operation.

Deactivation conditions for bi-fuel mode:

• Knock sensor error or continuosly engine knock.
• CNG shut off valve relay is faulty.
• CNG throttle error.

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Fault Codes
MID 128, PID 51 Throttle Position

MID 128: Engine control unit

FMI 3 – Voltage above normal or shorted high

Applicable engine type: TWG1663GE
Fault code explanation: Fault in throttle actuator circuit / Faulty throttle actuator.
Fault indication: Engine warning in DCU/DU display.
Symptom: Bi-fuel mode is deactivated.
Conditions for fault code: Voltage on pin B24 on EECU > 4.75 V for 5 seconds.
Possible reason: • Open circuit in throttle actuator supply cable and PWM cable.
• Short circuited throttle actuator supply cable to actuator negative
cable.
• Faulty throttle position sensor.
Suitable action: 1 Check all the cables and connectors between the throttle actuator
and the EECU.
Please refer to Fault tracing of cables and connectors page 38.
2 Check the contact pressure in the throttle actuator connector and in
socket B24 in the EECU connector.
3 Check the throttle actuator.
Measurements: Checking the throttle actuator page 135

FMI 5 – Voltage below normal or shorted to lower voltage.

Applicable engine type: TWG1663GE
Fault code explanation: Fault in throttle actuator circuit / Faulty throttle actuator.
Fault indication: Engine warning in DCU/DU display.
Symptom: Bi-fuel mode is deactivated.
Conditions for fault code: Voltage on pin B24 on EECU < 0.25 V for 5 seconds.
Possible reason: • Open circuit in throttle actuator supply cable.
• Open circuit in throttle position cable.
• Short circuited throttle position cable to throttle actuator negative
cable.
• Short circuited throttle actuator supply cable to throttle position cable.
• Faulty throttle actuator sensor.
Suitable action: 1 Check all the cables and connectors between the throttle actuator
and the EECU.
Please refer to Fault tracing of cables and connectors page 38.
2 Check the contact pressure in the throttle actuator connector and in
socket B24 in the EECU connector.
3 Check the throttle actuator.
Measurements: Checking the throttle actuator page 135

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FMI 7 – Mechanical system not responding properly

Applicable engine type: TWG1663GE
Fault code explanation: Deviation between demanded throttle position and actual throttle position.
Fault indication: Engine warning in DCU/DU display.
Symptom: Bi-fuel mode is deactivated.
Conditions for fault code: Too large deviation between demanded throttle position and actual throttle
position for more than 5 seconds.
Possible reason: • Frozen throttle actuator.
• Faulty PWM signal cable.
• Throttle position signal disturbed.
• Internal throttle actuator error.
Suitable action: 1 Check all the cables and connectors between the throttle actuator
and the EECU.
Please refer to Fault tracing of cables and connectors page 38.
2 Check the throttle actuator.
Measurements: Checking the throttle actuator page 135

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Circuit description
A throttle actuator is used to control the CNG throttle.
The actuator is supplied with battery voltage.

The EMS is controlling the amount of gas injected

into the inlet manifold by controlling the throttle posi-
tion. The EMS is using a PWM signal to control the
position of the throttle.

The throttle position is monitored by a Hall effect sen-

sor. The output signal is a linear voltage signal. The
P0016258 output range should be approximately 0.75 VDC
when the throttle is closed and approximately 4.25
VDC when the throttle is fully opened. The throttle is
spring forced to closed position.

Sensor EMS Signal type Signal description

Pin 1 – Bat + Actuator supply +
Pin 2 B24 0.75-4.25 V Throttle position
Pin 3 – Bat - PWM -
Pin 5 – Bat - Actuator supply -
Pin 11 B54 PWM PWM + B24

Component location
The throttle actuator is mounted on the inlet manifold.

P0016259

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MID 128, SID 76 Knock sensor

MID 128: Engine control unit

FMI 0 – Data valid but above normal operational range

Applicable engine type: TWG1663GE
Fault code explanation: Excessive knocking is detected at knock sensor #1.
Fault indication: Engine warning in DCU/DU display.
Possible concurrent displayed MID 128, PID 51 Throttle Position page 126
fault code:
Symptom: • Power loss. Derate according to the engine protection map.
• Bi-fuel mode is deactivated.
Preconditions: Knock control is only performed in bi-fuel mode.
Conditions for fault code: The vibrations at the sensor exceeds a preset threshold value for more
than 20 ms.
Possible reason: • Too much gas injected.
• Poor gas quality.
Suitable action: 1 Check the throttle function.
2 Check that the quality, of the gas used, fulfills the requirements.
Measurements: Checking the throttle actuator page 135

FMI 9 – Abnormal update rate

Applicable engine type: TWG1663GE
Fault code explanation: Knock sensor #1 senses the knock level at cylinders 4-5-6.
Fault indication: Engine warning in DCU/DU display.
Symptom: • Power loss. Derate according to the engine protection map.
• Bi-fuel mode is deactivated.
Conditions for fault code: • The vibrations at the sensor are lower than a preset threshold value.
• Knock control is only performed in bi-fuel mode.
Possible reason: • Open circuit in the wiring between the sensor and the EMS.
• Faulty sensor.
Suitable action: 1 Check the cable harness and connectors between the sensor and the
EMS2.
Please refer to Fault tracing of cables and connectors page 38.
2 Check the sensor.
Measurements: Checking the knock sensor page 137

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Circuit description
The knock sensor consists of a piezo-electric ele-
ment that translates vibrations into an electric signal
that is proportional to the acceleration.

The knock signal is evaluated for each cylinder. The

signal from the sensor is evaluated at a mapped
angle interval around TDC. The angle interval is
mapped against current engine speed. Knock is indi-
cated if the signal is relatively higher than the back-
ground vibrations. When knocking is detected, the
diesel-gas factor is lowered. If the knocking persists,
a fault code is set and the bi-fuel mode is deacti-
P0016264
vated.

The engine vibrations are roughly estimated from

engine speed and load. If the estimated vibration
level is too low, a sensor error fault code is set.
Knock sensor #1 senses the knock level at cylinders
4-5-6.

Sensor EMS Signal type

Pin 1 B35 Bat -
Pin 2 B40 Voltage (amplitude depends
on the knock level)

P0016265

Component location
Knock sensor #1 is located on the engine block at
the left side of the engine near cylinder 5.

P0016266

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MID 128, PSID 128 Knock sensor#2

MID 128: Engine control unit

FMI 9 – Abnormal update rate

Applicable engine type: TWG1663GE
Fault code explanation: Knock sensor #2 senses the knock level at cylinders 1-2-3.
Fault indication: Engine warning in DCU/DU display.
Symptom: • Power loss. Derate according to the engine protection map.
• Bi-fuel mode is deactivated.
Conditions for fault code: • The vibrations at the sensor are lower than a preset threshold value.
• Knock control is only performed in bi-fuel mode.
Possible reason: • Open circuit in the wiring between the sensor and the EMS.
• Faulty sensor.
Suitable action: 1 Check the cable harness and connectors between the sensor and the
EMS2.
Please refer to Fault tracing of cables and connectors page 38.
2 Check the sensor.
Measurements: Checking the knock sensor page 137

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Circuit description
The knock sensor consists of a piezo-electric ele-
ment that translates vibrations into an electric signal
that is proportional to the acceleration.

The knock signal is evaluated for each cylinder. The

signal from the sensor is evaluated at a mapped
angle interval around TDC. The angle interval is
mapped against current engine speed. Knock is indi-
cated if the signal is relatively higher than the back-
ground vibrations. When knocking is detected, the
diesel-gas factor is lowered. If the knocking persists,
a fault code is set and the bi-fuel mode is deacti-
P0016264
vated.

The engine vibrations are roughly estimated from

engine speed and load. If the estimated vibration
level is too low, a sensor error fault code is set.
Knock sensor #2 senses the knock level at cylinders
1-2-3.

Sensor EMS Signal type

Pin 1 B35 Bat -
Pin 2 B36 Voltage (amplitude depends
on the knock level)

P0016265

Component location
Knock sensor #2 is located on the engine block at
the left side of the engine near cylinder 2.

P0016270

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MID 128, PSID 137 Compressed

natural gas shut off valve relay

MID 128: Engine control unit

FMI 3 – Voltage above normal or shorted high

Applicable engine type: TWG1663GE
Fault code explanation: Fault in CNG shut off relay circuit / Faulty CNG shut off relay.
Fault indication: Engine warning in DCU/DU display.
Symptom: Bi-fuel mode is deactivated.
Conditions for fault code: Current on pin B46 on EECU > 5.5 A.
Possible reason: Short circuit in the CNG shut off valve relay / relay circuit.
Suitable action: 1 Check all the cables and connectors between the relay and the EMS.
Please refer to Fault tracing of cables and connectors page 38.
2 Check the relay.

FMI 4 – Voltage below normal or shorted low

Applicable engine type: TWG1663GE
Fault code explanation: Fault in CNG shut off relay circuit / Faulty CNG shut off relay.
Fault indication: Engine warning in DCU/DU display.
Symptom: Bi-fuel mode is deactivated.
Conditions for fault code: Voltage on pin B46 on EECU < 1/3 Bat+.
Possible reason: Short circuit in the CNG shut off valve relay / relay circuit.
Suitable action: 1 Check all the cables and connectors between the relay and the EMS.
Please refer to Fault tracing of cables and connectors page 38.
2 Check the relay.

FMI 5 – Voltage below normal or shorted to lower voltage.

Applicable engine type: TWG1663GE
Fault code explanation: Fault in CNG shut off relay circuit / Faulty CNG shut off relay.
Fault indication: Engine warning in DCU/DU display.
Symptom: Bi-fuel mode is deactivated.
Conditions for fault code: 2/3 Bat+ > Voltage on pin B46 on EECU > 1/3 Bat+.
Possible reason: Open circuit in the CNG on/off valve relay/relay circuit.
Suitable action: 1 Check all the cables and connectors between the relay and the EMS.
Please refer to Fault tracing of cables and connectors page 38.
2 Check the relay.

47702556 02-2012 133

30-3 Bi-Fuel Engines

Circuit description
The EMS is controlling the activation / deactivation of
the CNG, bi-fuel, mode. Pin 86 on the gas mode acti-
vation relay is connected to battery positive via the
main relay. The EMS is activating CNG mode by
grounding pin B46.

A Example of customer interface.

P0016271

134 47702556 02-2012

 30-3 Bi-Fuel Engines

Measurements
Checking the throttle actuator
Description: The throttle controls the amount of gas injected into the inlet manifold.
Special tools: 88890074 Multimeter
9998699 Break-out box
88890016 Break-out cable
Measurement procedure: 1 Turn the main switch off.
2 Perform Fault tracing of cables and connectors page 38.
3 Connect according to the schematic diagram. Use 88890016 Break-
out cable.
4 Turn the main switch on.
5 Turn the ignition on.
6 Start measurement 1.
7 Connect according to the schematic diagram. Use 9990014 Break-
out cable.
8 Start measurement 2.
Measurement points:
(1) 24-28 (88890016) 88890016: 24 (supply +), 28 (supply -)
U ≈ Ubat
(2) B24-B59 (9990014) 9990014: B24 (throttle position output), B59 (supply -)
U ≈ 0.75-4.25 VDC (closed-open)

47702556 02-2012 135

30-3 Bi-Fuel Engines

Schematic diagram:

P0016275

P0016276

136 47702556 02-2012

 30-3 Bi-Fuel Engines

Checking the knock sensor

Description: The knock sensor monitors the engine vibrations.
Special tools: 88890074 Multimeter
9998699 Break-out box
88890161 Break-out cable
Measurement procedure: 1 Turn the main switch off.
2 Perform Fault tracing of cables and connectors page 38.
3 Connect according to the schematic diagram.
4 Tap the engine block with a spanner while reading the multimeter.
The voltage level depends of the tapping force.
Measurement points: 1 (+), 2 (-)
1–2 U -> mVAC, depends of the tapping force
Schematic diagram:

P0016277

47702556 02-2012 137

 BATT.+
SWITCHED CAN BATT.+ 1708
CAN 1708 J1939 BATT.- SWITCHED J1587 BATT.+

47702556 02-2012
J1939 J1587
HL BATT.+ STOP AB BATT.-
HL AB 10
1 2 3 4 5 6 34 7 1 2 3 4 5 6 7 8 1 2 3 4 5 6 2 1 36

W/SB

Y/GR

BN/P
R/BL 1,5

SB 4
R/BL 1,5
CAN 2

R4
GN/SB

SB
SB 2,5

W
W/SB

R
GR/Y

R 2,5
Y/W

W
W/SB
R/BL 1 W
5
86
23 Y/SB
1
85
2 1 R/BL 1,5 R/BL 1,5 87
2
Wiring Diagram TAD56x

GR/OR
SB

30
4 6 R 1,5
Y

SB 2 4
3 1234567
1 R
3
SB
Y

38 5
37 21

CAN 3
24 SB 2,5
4M
R
4
SB 8 SB
2 SB 2
3
1 2P 1R 2 1
P5 SB 1
θ
2
SB SB
4 1 θ R/BL 1,0
R
1
2P 11

BN/OR 1,0
25

R/BL 1,5
R/BL 1,5
R/W 1,0
GN/SB

OR 1,0
BL/OR
GN/BL

BL/GN

BN 1,0

BL/GR
SB 1,0

SB 1,0

SB 1,5
SB 1,5
SB 1,5
GR/W

GN/W

BL/W

Y/GR

GR/Y
R 1,0

BN/P
LBN

Y/W
30

R/Y
GR
VO
BL

Y
1 5 24 11 16 17 18 31 27 3 4 49 23 10 8 52 56 22 21 29 25 37 57 60 7 58 59 61 51 55
h l h l h l
CONNECTOR B

R 2,5
CONNECTOR A BA
31 11 7 47 22 19 35 39 45 46 37 38 12 16 48 40 36 56 59 60 8 33 34 27 58 57
- +
GR/GN

GN
SB 1,0

R 1,0

OR/SB
GR/SB

GR/SB
VO/SB

W 1,0

W 1,0

W 1,0

W 1,0

Y/SB

W/SB

R/BL 1,5
BL

W 2,5

W 2,5

SB 1,5
GR/OR

BN/OR

OR
GR/W

W
GN/W
37-0 Wiring Diagrams

RY
9 33
R CYL. 1 4321
3
SB 1 θ2 1 2
4321
P4 MAIN RELAY HOLD 19 35
R CYL. 2
3
2

R 2,5

R 2,5
SB 1

OR 1,0
1 2
P 17
CYL. 3
26 1 2 2 1

R/BL 1,5
n n 1 2
1 2 R 25
3
18
37-0 Wiring Diagrams

32
13 14 CYL. 4
20

SB 4
R/W
R/Y
R4
BC AE D F 1 2 12345 SB 25

P0015340
16 B+ B- SB 25
G 31
30
n 4 R 25 3
2
39

1
1 - +
 37-0 Wiring Diagrams

Description for wiring diagram TAD56x

1 Battery Cable colors
BL = Blue
2 Main switch
LBL = Light blue
3 Starter motor BN = Brown
LBN = Light brown
4 Alternator
GN = Green
5 Main relay GR = Gray
OR = Orange
6 Aux stop
P = Pink
7 6-pole connector, engine interface R = Red
SB = Black
8 Sensor, Coolant temperature
VO = Purple
9 Sensor, Boost air pressure / Air Temperature W = White
Y = Yellow
10 VODIA J1587 (diagnosis conn.)
Cable cross section = 0.75 mm2 unless otherwise
11 Sensor, Ambient air temperature stated.
12
Visco electric fan
13 Sensor, Camshaft C = Clutch control low
14 Sensor, Flywheel (crank) B = Clutch control high
A = Fan speed sensor supply
15 E = Fan speed output
16 Unit injectors (4-cyl. engine) D = Fan speed sensor ground
F = Not connected
17 Preheater relay
18 Fuse preheater
19 Fuse 10A
20 Preheater
21 Switch, Coolant Level
22
23 Sensor, Water in Fuel
24 Sensor, Oil pressure
25 Sensor, Fuel Pressure
26 Sensor, Rail pressure
27
28
29
30 Engine Control Unit, EMS 2.2 (MID 128)
31
32 MPROP
33 4-pole connector, preaheater relay
34 6-pole connector, EATS
35 Fuse 30A, EATS
36 2-pole connector, power supply EATS
37 Throttle
38 Sensor, Oil level / Oil temperature
39 Throttle

47702556 02-2012 1

 BATT.+
SWITCHED CAN BATT.+ 1708
CAN 1708 J1939 BATT.- SWITCHED J1587 BATT.+

47702556 02-2012
J1939 J1587
HL BATT.+ STOP AB BATT.-
HL AB 10
1 2 3 4 5 6 34 7 1 2 3 4 5 6 7 8 1 2 3 4 5 6 2 1 36

W/SB

Y/GR

BN/P
R/BL 1,5

SB 4
R/BL 1,5
CAN 2

R4
GN/SB

SB
SB 2,5

W
W/SB

R
GR/Y

R 2,5
Y/W

W
W/SB
R/BL 1 W
5
86
23 Y/SB
1
85
2 1 R/BL 1,5 R/BL 1,5 87
2
Wiring Diagram TAD76x

GR/OR
SB

30
4 6 R 1,5
Y

SB 2 4
3 1234567
1 R
3
SB
Y

38 5
37 21
CAN 3
24 SB 2,5
4M
R
4
SB 8 SB
2 SB 2
3
1 2P 1R 2 1
P5 SB 1
θ
2
SB SB
4 1 θ R/BL 1,0
R
1
2P 11

BN/OR 1,0
25

R/BL 1,5
R/BL 1,5
R/W 1,0
GN/SB

OR 1,0
BN 1,0
BL/OR
GN/BL

BL/GN

BL/GR
SB 1,0

SB 1,0

SB 1,5
SB 1,5
SB 1,5
GR/W

GN/W

BL/W

Y/GR

GR/Y
R 1,0

BN/P
LBN

Y/W
30

R/Y
GR
VO
BL

Y
1 5 24 11 16 17 18 31 27 3 4 49 23 10 8 52 56 22 21 29 25 37 57 60 7 58 59 61 51 55
h l h l h l
CONNECTOR B

R 2,5
CONNECTOR A BA
31 11 7 47 22 19 35 39 45 46 37 38 12 16 36 40 44 48 52 56 59 60 8 33 34 27 58 57
- +
GR/GN

GN
SB 1,0

R 1,0

OR/SB
GR/SB

GR/SB
VO/SB

W 1,0
W 1,0

W 1,0

W 1,0

W 1,0

W 1,0

Y/SB

W/SB

R/BL 1,5
BL

W 2,5

W 2,5

SB 1,5
GR/OR

BN/OR

OR
GR/W

W
GN/W
RY
9 33
R 3 CYL. 1 4321
SB 1 θ2 1 2
4321
P4 MAIN RELAY HOLD 19 35
R CYL. 2
3
2

R 2,5

R 2,5
SB 1

OR 1,0
1 2
P 17
CYL. 3
26 1 2 2 1

R/BL 1,5
n n 1 2
1 2 R 25
3
18
37-0 Wiring Diagrams

32
13 14 CYL. 4
20

SB 4
R/W
R/Y
R4
BC AE D F 1 2 12345 SB 25
CYL. 5 B+ B- SB 25

P0015341
G 31
M 30
n 1 2 4 R 25 3
CYL. 6
2
39 1 2

14
1 - +
16
 37-0 Wiring Diagrams

Description for wiring diagram TAD76x

1 Battery Cable colors

BL = Blue
2 Main switch
LBL = Light blue
3 Starter motor BN = Brown
LBN = Light brown
4 Alternator
GN = Green
5 Main relay GR = Gray
OR = Orange
6 Aux stop
P = Pink
7 6-pole connector, engine interface R = Red
SB = Black
8 Sensor, Coolant temperature
VO = Purple
9 Sensor, Boost air pressure / Air Temperature W = White
Y = Yellow
10 VODIA J1587 (diagnosis conn.)
Cable cross section = 0.75 mm2 unless otherwise
11 Sensor, Ambient air temperature stated.
12
Visco electric fan
13 Sensor, Camshaft C = Clutch control low
14 Sensor, Flywheel (crank) B = Clutch control high
A = Fan speed sensor supply
15 E = Fan speed output
16 Unit injectors (6-cyl. engine) D = Fan speed sensor ground
F = Not connected
17 Preheater relay
18 Fuse preheater
19 Fuse 10A
20 Preheater
21 Switch, Coolant Level
22
23 Sensor, Water in Fuel
24 Sensor, Oil pressure
25 Sensor, Fuel Pressure
26 Sensor, Rail pressure
27
28
29
30 Engine Control Unit, EMS 2.2 (MID 128)
31
32 MPROP
33 4-pole connector, preaheater relay
34 6-pole connector, EATS
35 Fuse 30A, EATS
36 2-pole connector, power supply EATS
37 Throttle
38 Sensor, Oil level / Oil temperature
39 Throttle

47702556 02-2012 14

37-0 Wiring Diagrams

Wiring Diagram TAD136x / TAD166x

0.75 SB

0.75 SB
0.75 SB

0.75 GN/OR

21
24 P
EA31 EB49 1 BN
0.75SB 1SB EA11 EB3 0.75 GN/SB
0.75R
B
1R 0.75 GN/W

3 4
C EA7 EB4
0.75R

1
A

0.75 BL/GN
0.75 BN/OR EB31
E

28
EA47
D

0.75 GN/GR 0.75 BL/OR

0.75 R EA22 EB11
0.75SB EA15 EB16 0.75 GN/R

20
P

22
0.75OR EA29

2
0.75GN

P
P
EA35
0.75BL

4
EA39

1
0,75 SB
0,75R
0.75 OR/SB
EA45
25 26
0.75 GN/SB
EA46 1R 0,75R
EB17
0.75 GR/W
EA37
0.75 OR/SB 1SB 0.75 SB
EA38 EB18
1Y 0.75 SB
EA36

0,75R
1Y

0.75 SB
EA40

23
1Y EA44
1Y
EA48

1
1Y

P
EA52 0.75 GR/R

1 SB
1Y EA56 EB28

1
4

2
2

19
1Y
EA28 0.75 BN/OR
1Y EA32 EB27
1Y EA12 1R
1Y
EA16 EB5 0.75 BL
1Y EA20 0.75 VO

1 23 4 5
1Y EB1
EA24
0.75 GR
EB24

18
27

0.75 W
1

17
30

1Y
1Y

0.75 SB
EB10 0.75 SB
1Y 0.75 Y

1 2 3 4 5 6
1Y 1Y EA59 EB8 0.75 SB
1Y
1Y

1Y 1Y
1Y EA62

9
1Y 0.75 P
1Y 1Y EB22
EA60 0.75 BN/P
1Y EB21
1Y
1Y
7
EA61

8
0.75 BL/W
0.75 Y/SB EB52 J1939 H

1 2 3 4
EA8 0.75 BL/GR
EB56 J1939 L
1.5 BL/R BAT + (MAIN RELAY)
0.75 W/SB EB38 0.75 GN
EA33
0.75 W
0.75 Y/SB J1708 A

5 6
EB29 0.75 W/SB
0.75 W J1708 B
EA34
16
0.75 BL/R

1 OR
EB25
0.75 BL EA27 0,75 R/W
EB37

1.5 BL/R EA58 EB57 1.5 BL/R

6

1.5 BL/R 1.5 BL/R

1.5 SB EA57 EB60
31

1 BN
EB7
0.75 BL/W
EA23
0.75 BN
EA43 EB58 1.5 SB
1.5BL/R

1.5 SB
EB59

1.5 SB
EB61

EB51 0.75 Y/W

7

0.75 Y/GR
EB55
J1939 H
1 2 3 4
4

J1939 L
2.5 SB
BAT -
2.5 R
BAT +
1 2 34 5

1 BL/R
BAT. SWITCED
G

5 6 7 8

STOP
0.75 W
J1708 A
0.75 W/SB
J1708 B
25 SB

2.5 SB

10 1
25 R

0.75 R
BAT +
0.75 W/SB
J1708 B
2 3 4

4 SB 0.75 SB
BAT -
CAN 3 HIGH
0.75 W
J1708 A
5

SB
- M+
1

SW

R
2

25 SB

R
3

12

4R 2.5 R 2.5 R
11 2
2

1
13

4 SB
4R 4R
1
1
2

15
2
25 R

1 BN
4 3 2 1

4 3 2 1

1 OR
1
2
14

1 BL/R 1 BL/R
1 SB
3
1

P0012461

14 47702556 02-2012

 37-0 Wiring Diagrams

Description for wiring diagram TAD136x /

TAD166x VE

1 Battery Cable colors

BL = Blue
2 Main switch
LBL = Light blue
3 Starter motor BN = Brown
LBN = Light brown
4 Alternator
GN = Green
5 Main relay GR = Gray
OR = Orange
6 Aux stop
P = Pink
7 6-pole connector, engine interface R = Red
SB = Black
8 6-pole connector, EATS
VO = Purple
9 6-pole connector, WF W = White
Y = Yellow
10 VODIA input (diagnosis conn.)
Cable cross section = 0.75 mm2 unless otherwise
11 2-pole connector, power supply EATS stated.
12 Fuse, main circuit 10 A
Visco electric fan
13 Fuse, power supply EATS 30 A C = Clutch control low
14 Fuse, pre-heating B = Clutch control high
A = Fan speed sensor supply
15 4-pole connector, pre-heating E = Fan speed output
16 Valve, VGT control D = Fan speed sensor ground
F = Not connected
17 Switch, Coolant Level
18 Throttle (EATS)
19 Sensor, Coolant temperature
20 Sensor, Oil pressure
21 Sensor, Oil level / Oil temperature
22 Sensor, Fuel Pressure
23 Sensor, Crankhouse pressure
24 Sensor, Boost air pressure / Air Temperature
25 Sensor, Camshaft
26 Sensor, Flywheel (crank)
27 Control unit EMS 2.2
28 Air filter indicator
29 Visco elecric fan
30 Unit injector (Cyl 1-6)
31 Sensor, Humidity / Air Temperature (EATS)

47702556 02-2012 14

37-0 Wiring Diagrams

Wiring Diagram TWD 1663 GE / TWG 1663

NOTICE! Wiring diagram used for both engine types, TWD and TWG together.

7
0.75 SB
0.75 SB POWER

1 2 3 4 5 6 7 8 9 10 11 12
B C A E D F
B C A E D F
THROTTLE POSITION

30
0.75 GN/OR

22
PWM -
EA31 EB49 1 BN
32
0.75SB 1SB EA11 EB3 0.75 GN/SB

P
0.75R GROUND
B 1R 0.75 GN/W

3 4
EA7 EB4
C
0.75R

1
A

0.75 BL/GN
0.75 BN/OR EB31
E

1 BL/R
EA47
D

0.75 GN/GR
EA22 EB11 0.75 BL/OR
31 P EB9 0.75 BL

2
23
0.75SB

20 P
EA15
0.75OR 0.75 GN
EA29 EB13

2
0.75GN 0.75 GN/R
EA35 EB16 PWM +

P
0.75BL

4
EA39

1
4
0,75 SB
0.75 OR/SB

1
0,75R

24
EA45
33 34
0.75 GN/SB
EA46 1R 0,75R
EB17
0.75 GR/W
EA37
0.75 OR/SB 1SB 0.75 SB
EA38 EB18
1Y 0.75 SB
EA36

0,75R
1Y

0.75 SB
EA40
1Y

25 P

21
EA44
1Y
EA48

1 2 3 4
1
1Y EA52 0.75 GR/R 0.75 W/SB
1Y EA56 EB28

1
4

2
2
1Y
EA28 EB27 0.75 BN/OR
1Y EA32 0.75 GR

9
1Y EB24
EA12

1 2 3 4
1Y
EA16 EB54 0.75 VO 0.75 W/SB
1Y EA20 EB35 0.75 W/SB

2
1Y EA24 EB36 0.75 P/SB
0.75 P/W
EB40
0.75 VO
EB34
2 4 3 1

2 4 3 1

2 4 3 1

2 4 3 1

2 4 3 1

2 4 3 1

28
35

1
26
0.75 W
EB23

4
1

2
30

1Y
1Y

0.75 SB
EB10 0.75 SB
1Y 0.75 Y

0.75 BL/R
1 2 3 4 5 6
1Y 1Y EA59 EB8 0.75 SB
1Y
1Y

1Y 1Y
1Y EA62

27
0.75 BL/R
1Y 0.75 P
1Y 1Y EB22
EA60 0.75 BN/P
1Y EB21
1Y
1Y
7
EA61

10 1
0.75 BL/W
0.75 Y/SB EB52 J1939 H
EA8 0.75 BL/GR
EB56 J1939 L

2 3 4
1.5 BL/R BAT + (MAIN RELAY)
0.75 W/SB EB38 0.75 GN
EA33
0.75 W
0.75 Y/SB J1708 A

5 6
EB29 0.75 W/SB
2

0.75 W J1708 B
297

0.75 BL/R

EA34
1 OR
EB25
1

0.75 BL EA27 0,75 R/W 0.75 BL/R

11
EB37

1.5 BL/R EA58 EB57 1.5 BL/R BAT. SWITCED

1
ON/OFF

2
0.75 SB

1.5 BL/R
1.5 SB EA57 EB60
6

1 BN
EB7
1.5 BL/R
1.5 SB
1.5BL/R

EB58 12
1.5 SB
EB59

1.5 SB LOAD INPUT

1

1
EB61
GAS REQUEST
2

EB51 0.75 Y/W 2

13 1

0.75 Y/GR
EB55
0.75 GR/W J1939 H
EB46
0.75 BN/SB J1939 L
2 3 4

EB47 2.5 SB
4

0.75 BN/W BAT -

EB48 2.5 R
BAT +
1 2 34 5

1 BL/R
- G+

BAT. SWITCED
5 6 7 8

STOP
0.75 W
J1708 A
0.75 W/SB
J1708 B
25 SB

2.5 SB

14
25 R

0.75 R
BAT +
1 2 3 4

0.75 W/SB
J1708 B
4 SB 0.75 SB
BAT -
CAN 3 HIGH
0.75 W
J1708 A
5 6

SB CAN 3 LOW
- M+
SW
1

4 5 1

R
87
30 86
2
87a 85

5 0.75 R
25 SB

R
3
2

1.5 R

15

4R 2.5 R 2.5 R
2

1
16

4 SB
2 1

4R 4R
1
2
17
2

19

1 BN
4 3 2 1

4 3 2 1
25 R

1 OR
1
18

1 BL/R 1 BL/R
3

1 SB
1

P0015343

14 47702556 02-2012

 37-0 Wiring Diagrams

Description for wiring diagram TWD 1663

GE / TWG 1663

1 Battery Cable colors

BL = Blue
2 Main switch
LBL = Light blue
3 Starter motor BN = Brown
LBN = Light brown
4 Alternator
GN = Green
5 Main relay GR = Gray
OR = Orange
6 Aux stop
P = Pink
7 12-pole connector, Gas throttle (gas valve) R = Red
SB = Black
8 4-pole connector, Knock sensor 1
VO = Purple
9 4-pole connector, Knock sensor 2 W = White
Y = Yellow
10 6-pole connector, EATS
Cable cross section = 0.75 mm2 unless otherwise
11 2-pole connector, Gas supply valve stated.
12 2-pole connector, Gas flow, Alternator load
Visco electric fan
13 8-pole connector, Engine interface C = Clutch control low
14 6-pole connector, VODIA diagnos B = Clutch control high
A = Fan speed sensor supply
15 2-pole connector, power supply EATS E = Fan speed output
16 Fuse, main circuit engine, 10A D = Fan speed sensor ground
F = Not connected
17 Fuse, power supply EATS 30 A
18 Fuse, pre-heating
19 4-pole connector, pre-heating
20 Sensor, Oil pressure
21 Sensor, Coolant temperature
22 Sensor, oil level temp
23 Lisk valve (wastegate)
24 Sensor, Fuel Pressure
25 Sensor, Crankhouse pressure
26 Cold start valve
27 6-pole connector, WIF
28 Switch, Coolant Level
29 Wastegate Valve
30 Unit injector (Cyl 1-6)
31 Air filter indicator
32 Visco electric fan
33 Sensor, Camshaft
34 Sensor, Flywheel (crank)
35 Control unit EMS 2.2

47702556 02-2012 14

37-0 Wiring Diagrams

Wiring Diagram SCR-system UDS2 TAD 56x, 76x, 136x, 166x VE

1 Y/W
22

2
1 R/SB

SPLICE 1
1 R/SB
2

1 R/SB

1
4

2
1 BL/W
32

1P/W
34

SPLICE 2
1 R/W
5

1
1,5 R/W
1

1 R/W

1
6

1GN/W 2
35

1 R/W
1
7

1BN/SB
33 19

0.75 SB
0.75 R
30

1/4
8

3
2

0.75 BN/OR
18

0.75 GN/GR
9
29

1/4

0.75 OR/SB
UDS2
28

0.75 GR/SB
17

0.75 Y/R
12

1
10

0.75 OR
11

SPLICE 3

2.5 SB
14

4 SB BAT -
2.5 SB
2

1
15

4R
BAT +
1

2.5 R SPLICE 4
3

2.5 R
4

0.75 BL/W SPLICE 5 0.75 BL/W

5

SPLICE 6 0.75 BL/GR

0.75 BL/GR
6

1.5 BL/R
24

0.75 W
20

0.75 W/SB
31

J1939 H
1
0.75 BL/W

0.75 BN
J1939 L
23

0.75 Y
11
0.75 BL/GR

0.75 SB

0.75 R

BAT.SWITCHED
3
7

4
8

12

2
3
1 2

J1708 A
1

5
N0x

J1708 B
6

0.75 R
P0012460

14 47702556 02-2012

 37-0 Wiring Diagrams

Description for wiring diagram SCR-

system with UDS2 TAD 56x, 76x, 136x,
166x VE
1 2-pole connector, power supply SCR
2 6-pole connector, SCR
3 Heater (Suction line from AdBlue tank)
4 Heater (Pressure line to dosing valve)
5 Heater (Return line from dosing valve)
6 Heater (Return line to AdBlue tank)
7 Heater (AdBlue bottom filter heater)
8 Sensor, AdBlue tank temperature / Adblue tank
level
9 Sensor, Exhaust Temperature
10 Dosing valve (AdBlue injector)
11 Sensor, NOx
12 Valve, AdBlue tank heating

Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Grey
OR = Orange
P = Pink
R = Red
SB = Black
VO = Purple
W = White
Y = Yellow
Cable cross section = 0.75 mm2 unless otherwise
stated.

47702556 02-2012 14

37-0 Wiring Diagrams

Wiring Diagram SCR-system UDS2 TWG TWD 1663 GE

22
1 Y/W

2
1 R/SB

SPLICE 1
1
1 R/SB
2

1 R/SB

1
4
1 BL/W

2
32

1 P/W
34

2
1 R/W

SPLICE 2
1,5 R/W
1

1 R/W

10
1
6

1 BN/SB
33 19 30

1 2

3
NOx
0,75 SB

4
0,75 BL/GR
0,75 BL/W
0,75 R
1
3

14
7

0,75 R
4
2

0,75 BN/OR
18 29

0,75 GN/GR
UDS2

14

0,75 OR/SB
8
28

0,75 SB
0,75 GR/SB
17

0,75 Y/R
12

1
9

0,75 OR
2
11

SPLICE 3

2,5 SB
14

4 SB
2,5 SB BAT -
2
15

4R
BAT +
1

2,5 R
3

SPLICE 4

SPLICE 5

2,5 R
4

0,75 BL/W
5

0,75 BL/GR
6

0,75 BL/W
SPLICE 6

1,5 BL/R
0,75 BL/GR
24

0,75 W
20

0,75 W/SB
31

J1939 H
1

0,75 BN
23

J1939 L
2 3 4 5 6

0,75 Y
BAT.SWITCHED
7

4
11
8

J1708 A
1

J1708 B
P0002041 0,75 R

1 47702556 02-2012

 37-0 Wiring Diagrams

Description for wiring diagram SCR-

system with UDS2 TWG TWD 1663 GE
1 2-pole connector, power supply SCR
2 6-pole connector, SCR
3 Heater (Suction line from AdBlue tank)
4 Heater (Pressure line to dosing valve)
5 Heater (Return line from dosing valve to Adblue
tank)
6 Heater (AdBlue bottom filter heater)
7 Sensor, AdBlue tank temperature / Adblue tank
level
8 Sensor, Exhaust Temperature
9 Dosing valve (AdBlue injector)
10 Sensor, NOx

Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Grey
OR = Orange
P = Pink
R = Red
SB = Black
VO = Purple
W = White
Y = Yellow
Cable cross section = 0.75 mm2 unless otherwise
stated.

47702556 02-2012 1

37-0 Wiring Diagrams

Wiring Diagram CIU

1 2 3 4 5 6 7 8 23
30

R/BL 1,5
GR/Y

R 2,5

W/SB
Y/W
SB 2,5 SB 1,5

W
14

SB 2,5
27
R 2,5 1
R 1,5
R/BL 1,5 R/BL 1,5
28
W
22
W/SB
37

R/BL 1,5
Y/W

SB 2,5
GR/Y

R 2,5
Y/W
12

W/SB
W
11 GR/Y

GN/Y
30 1 2 3 4 5 6 7 8 27
2

SB
GN/SB
2
1 2 3 4 5 6 7 8
3
GN/OR 26
24
29 R/W R

R/GR 8 SB SB
1
R/BN 9 R/SB
15
10

R/BL
R/Y

R/BL
R/BL
35

R/BL
SB
VO 11
41 7
SB
12

SB
P

SB
SB
16
25 3
R SB - 7
10 BN RPM/M + SB
R/SB R/SB
13

SB
4
33 GR/SB - P + 7
G SB
R/SB
LBN

SB
21
5
26 W/BL 13 R - C
+ 7
R/SB G
Y
20 6
BL/Y 14 R - C +
40
R/SB G
LBN
34

W/BN 15 R
9
W/GN 16
25

39 BL/OR 17

36 P/SB 18

7 VO/W 19

38 GL 20

R/GN 21
24

OR 22
17
R/SB 29
19
W/GL 28 1
SB
2
Y/BL R
8 3

P0014020

15 47702556 02-2012

 37-0 Wiring Diagrams

Description for wiring diagram CIU

1 Key switch (15+) Cable colors

BL = Blue
2 Rpm-potentiometer
LBL = Light blue
3 Tachometer (code 14) BN = Brown
LBN = Light brown
4 Oil pressure, Instrument
GN = Green
5 Oil temperature, Instrument GR = Gray
OR = Orange
6 Coolant temperature, Instrument
P = Pink
7 Instrument illumination R = Red
SB = Black
8 Idling contact, two-way
VO = Purple
9 1500 / 1800 rpm switch, two-way W = White
Y = Yellow
10 Starter contact, spring biased
Cable area = 0.75 mm2 unless otherwise specified.
11 Stop switch, spring biased
12 Diagnosis contact, spring return
13 Alarm, Low Oil Pressure
14 Alarm, High oil temperature
15 Alarm, High coolant temperature
16 Alarm, Low coolant level
17 Fuel alarm
18 Diagnostic lamp
19 Engine overspeed indication (GE) Horn (VE)
20 Operation indicator
21 Pre-heating indication
22 Pre-heating contact
23 8-pin connector engine interface
24 Governor switch
25 Battery Voltage Alarms
26 Termination resistance 120 Ohm
27 8-pin connector engine interface
28 Contact, engine protector disconnect
29 Easy Link connector block
30 Control Interface Unit (CIU)

47702556 02-2012 15

37-0 Wiring Diagrams

Wiring Diagram DCU

12345678 8
11

W/SB
Y/W

BL 2,5
R 2,5
GR/Y
SB 2,5
R/BL 1,5
W
1 Y/W

2 GR/Y

3 SB 2,5

4 R 2,5

5 R/BL 2,5

6 BL 2,5

7 W
W/SB

R/BL 1,5
8

SB 2,5

BL 2,5
W/SB
GR/Y
R 2,5
3

Y/W

W
1 1

1 VO 12345678 9
D 2 4
R/Y
C 2 1 2 3 4 5 6 7 8 10
U SB/Y
3
4 R/BL 5
Y 1
5 3
SB 2
6
7 GN/R

8 GN/Y 6
9 GN/SB
7
10 SB/VO

11 SB/GR

12 SB/W
P0004305

1 Stop contact Cable colors

BL = Blue
2 Start contact
LBL = Light blue
3 1-pin connector BN = Brown
LBN = Light brown
4 Horn, buzzer alarm
GN = Green
5 Easy Link connector GR = Grey
OR = Orange
6 Rpm-potentiometer
P = Pink
7 Indicator engine operation R = Red
SB = Black
8 8-pin connector engine interface
VO = Purple
9 8-pin connector engine interface W = White
Y = Yellow
10 Termination resistance 120 Ohm
Cable area = 0.75 mm2 unless otherwise specified.
11 Display Control unit (DCU)

15 47702556 02-2012

 37-0 Wiring Diagrams

PIN explanation EMS2.2, TAD 136x / TAD

166x VE

P0015342

47702556 02-2012 15

37-0 Wiring Diagrams

PIN explanation EMS2.2, TWD 1663 GE /

TWG 1663 GE, Table A-Connector

A07 V5EXT1 Supply

A08 Main relay hold
A11 V5EXT1 GND
A12 Injector ncv lsd 2 (Injector 2)
A15 Switch ground 1
A16 Injector sv lsd 2 (Injector 2)
A20 Injector ncv lsd 1 (Injector 1)
A22 Pressure input 1 (Boost pressure)
A24 Injector sv lsd 1 (Injector 1)
A27 Switch input 4 (External stop request input)
A28 Injector ncv lsd 3 (Injector 3)
A29 Switch input 7 (Air filter indicator)
A31 Fluid temp input 3 (Oil temp)
A32 Injector sv lsd 3 (Injector 3)
A33 J1708 B
A34 J1708 A
A35 Fan speed “+”
A36 Injector ncv lsd 6 (Injector 6)
A37 Crank speed “-”
A38 Crank speed ”+”
A39 Fan speed “-”
A40 Injector sv lsd 6 (Injector 6)
A44 Injector ncv lsd 5 (Injector 5)
A45 Cam speed “+”
A46 Cam speed “-”
A47 Air temp Input 1 (Boost temp)
A48 Injector sv lsd 5 (Injector 5)
A52 Injector ncv lsd 4 (Injector 4)
A56 Injector sv lsd 4 (Injector 4)
A57 ECU ground
A58 Switch input 1 (Key switch ignition)
A59 Injector sv hsd 1 (Injector bank 1)
A60 Injector sv hsd 2 (Injector bank 2)
A61 Injector ncv hsd 2 (Injector bank 2)
A62 Injector ncv hsd 1 (Injector bank 1)

15 47702556 02-2012

 37-0 Wiring Diagrams

PIN explanation EMS2.2, TWD 1663 GE /

TWG 1663 GE, Table B-Connector

B01 Throttle motor drive B

B03 Oil level L
B04 Oil level H
B05 Throttle motor drive A
B07 Switch input 8 (Preheater)
B08 Switch input 5 (Water in fuel indicator)
B09 Lisk valve / Wastegate Valve B
B10 Switch ground 2
B11 Pressure input 2 (Oil pressure)
B13 Lisk valve / Wastegate Valve A
B16 Pressure input 5 (Fuel Pressure)
B17 V5EXT2 Supply
B18 V5EXT2 Ground
B21 CAN 3 L
B22 CAN 3 H
B23 Switch input 6 (Coolant level indicator)
B24 Analog input 1 (throttle position sensor)
B25 Output on/off 6 (Preheat relay drive)
B27 Fluid temp input 2 (Coolant temp)
B28 Pressure Input 4 (Crank house pressure)
B29 Output on/off 6 (Starter relay driver LS)
B31 Air temp Input 3 (Ambient air temp)
B34 Output on/off 5 (Cold start valve)
B35 Knock sensor 1 & 2 GND (reference)
B36 Knock sensor 2 input
B37 Starter HS drive (Starter relay driver HS)
B38 Output PWM 5 (Wastegate valve B)
NOTICE! Will only be used on TWD engines until start of production of TWG engines
B40 Knock sensor 1 input
B46 Output PWM 6 (Gas valve on/off relay)
B47 Generator electric power
B48 Dual - fuel mode request
B49 Output PWM 2 (Cooling fan drive)
B51 CAN 1 H
B52 CAN 2 H
B54 Output PWM 7 (Gas throttle position demand)
B55 CAN 1 L
B56 CAN 2 L
B57 ECU Supply
B58 ECU GND
B59 ECU GND
B60 ECU Supply
B61 ECU GND

47702556 02-2012 15

37-0 Wiring Diagrams

PIN explanation UDS2

1 Supply “+” Electrical heaters (Return line from dosing valve / Return line to AdBlue tank / AdBlue bot-
tom filter heater)
2 Supply “+” Electrical heaters (Suction line from AdBlue tank / Pressure line to dosing valve)
3 Batt “+”
4 Batt “+”
5 CAN H J1939
6 CAN L J1939
7 CAN Termination resistor, jumper between pin 7 and 8 (Resistor inside ECU used)
8 CAN Termination resistor, jumper between pin 8 and 7 (Resistor inside ECU used)
9 N/A
10 N/A
11 Dosing valve “-” (AdBlue injector)
12 Dosing valve ”+” (AdBlue injector)
13 N/A
14 Batt “-”
15 Batt “+”
16 N/A
17 Catalyst exhaust temperature sensor “-” (GND)
18 AdBlue tank output level signal
19 AdBlue tank level/temperature “-2 (GND)
20 CAN J1708 A (Diagnostic interface)
21 N/A
22 Heater output 1 (Suction line from AdBlue tank)
23 Valve AdBlue tank heating “-” (GND)
NOTICE! Not used on TWG TWD GE engines
24 Terminal KL15 (Start UDS2 by “key-on” (+24V DC), After-run function, “key-off”, no voltage supply
on KL15 (0V DC), MID233 carry out after-run)
25 N/A
26 N/A
27 N/A
28 Supply “+” 5V DC Catalyst exhaust temperature sensor
29 AdBlue tank output temperature signal
30 Supply “+” 5V DC Urea tank level/temperature
31 J1708B (Diagnostic interface)
32 Heater output 2 (Pressure line to dosing valve)
33 Heater output 5 (AdBlue bottom filter heater)
34 Heater output 3 (Return line from dosing valve)
35 Heater output 4 (Return line to AdBlue tank)
NOTICE! Not used on TWG TWD GE engines

15 47702556 02-2012

 39-0 General

39-0 General
Index
Caption PID PPID SID PSID FMI
MID 128, PID 51 Throttle Position page 48 51 2, 3, 4, 5, 7, 11,
12, 13, 14
MID 128, PID 354 Relative Humidity page 54 354 3, 5
MID 128, PPID 270 NOx Sensor Gas Outlet page 56 270 2, 3, 5, 9, 12,
14
MID 128, PPID 272 Air temperature for humidity compensa- 272 4, 5
tion page 60
MID 128, PPID 273 Aftertreatment Reagent Pressure page 62 273 1, 2, 4, 5, 7, 9,
10, 13, 14
MID 128, PPID 274 After-treatment Reagent Tank Tempera- 274 0, 1, 4, 5
ture page 68
MID 128, PPID 275 After-treatment Reagent Filter Tempera- 275 0, 1, 2
ture page 71
MID 128, PPID 278 After-treatment Reagent Level page 74 278 3, 5, 11, 13, 14
MID 128, PPID 385 After-treatment Reagent Control Unit 385 3, 4, 12, 14
Voltage page 78
MID 128, PSID 7 Throttle Actuator page 81 7 3, 4, 5
MID 128, PSID 46 NOx monitoring failure page 84 46 0, 15
MID 128, PSID 77 ACM control unit EEPROM page 86 77 3, 4, 12
MID 128, PSID 85 After-treatment Reagent Dosing Sys ECU 85 6
Main Relay page 89
MID 128, PSID 87 After-treatment Reagent Pump Motor 87 0, 1, 10
Speed page 91
MID 128, PSID 89 After-treatment Reagent Dosing Valve 89 3, 4, 5, 7, 10,
page 94 14
MID 128, PSID 90 After-treatment Reagent Dosing System 90 1, 11, 14
page 98
MID 128, PSID 91 After-treatment Reagent Consumption 91 0, 1
page 99
MID 128, PSID 105 After-treatment Reagent Direction Valve 105 3, 4, 5, 7
page 102
MID 128, PSID 201 Data link, MID144 page 105 201 9
MID 128, PSID 229 SAE J1939 Data Link, SubNet 1, MID 229 9, 11
233 page 106
MID 128, PSID 232 SAE J1939-1 SubNet 1, Control link 232 2
page 107
MID 128, SID 232 5 V supply page 108 232 3, 4
MID 128, SID 253 Calibration memory EEPROM page 109 253 2, 12, 14

47702556 02-2012 15

39-0 General

(Bi-fuel)
Caption PID PPID SID PSID FMI
MID 128, PID 51 Throttle Position page 126 51 3, 5, 7
MID 128, SID 76 Knock sensor page 129 76 0, 9
MID 128, PSID 128 Knock sensor#2 page 131 128 9
MID 128, PSID 137 Compressed natural gas shut off valve 137 3, 4, 5
relay page 133

1 47702556 02-2012

Alphabetical index
A MID 128, PPID 385 After-treatment Reagent
About this Workshop manual..................................... 3 Control Unit Voltage ................................................ 78
MID 128, PSID 105 After-treatment Reagent
B Direction Valve ...................................................... 102
Bi-Fuel Engines...................................................... 125 MID 128, PSID 128 Knock sensor#2...................... 131
Bi-fuel mode, system description........................... 125 MID 128, PSID 137 Compressed natural gas
C shut off valve relay................................................. 133
Checking the aftertreatment direction valve........... 124 MID 128, PSID 201 Data link, MID144................... 105
Checking the aftertreatment reagent dosing valve. 121 MID 128, PSID 229 SAE J1939 Data Link,
Checking the aftertreatment reagent filter tem- SubNet 1, MID 233................................................. 106
perature sensor...................................................... 120 MID 128, PSID 232 SAE J1939-1 SubNet 1,
Checking the aftertreatment reagent pressure Control link ............................................................ 107
sensor..................................................................... 118 MID 128, PSID 46 NOx monitoring failure................ 84
Checking the aftertreatment reagent tank tem- MID 128, PSID 7 Throttle Actuator .......................... 81
perature and level sensor....................................... 122 MID 128, PSID 77 ACM control unit EEPROM ....... 86
Checking the combinated relative humidity MID 128, PSID 85 After-treatment Reagent
and temperature sensor......................................... 115 Dosing Sys ECU Main Relay ................................... 89
Checking the heaters (not electric heated hoses).. 119 MID 128, PSID 87 After-treatment Reagent
Checking the knock sensor.................................... 137 Pump Motor Speed ................................................. 91
Checking the NOx-sensor...................................... 117 MID 128, PSID 89 After-treatment Reagent
Checking the throttle actuator................................ 135 Dosing Valve ........................................................... 94
Checking the throttle mechanical position.............. 114 MID 128, PSID 90 After-treatment Reagent
Checking the throttle motor.................................... 114 Dosing System ........................................................ 98
Component description............................................ 26 MID 128, PSID 91 After-treatment Reagent
Concerned engines.................................................... 2 Consumption ........................................................... 99
MID 128, SID 232 5 V supply................................. 108
D
MID 128, SID 253 Calibration memory EEPROM . 109
Design and Function................................................ 19
MID 128, SID 76 Knock sensor.............................. 129
E
N
Electrical Welding..................................................... 35
Normal SCR operation and function......................... 24
F Normal SCR shutdown............................................. 25
Fault Codes...................................................... 48, 126
O
Fault Tracing............................................................ 48
Other Special Equipment......................................... 18
Fault tracing of cables and connectors..................... 38
P
G
Programming an empty control unit......................... 37
General......................................................... 2, 19, 159
General advice on working with EMS engines R
and UDS equipment................................................. 35 Repair instructions...................................................... 4
Glossary for SCR..................................................... 20 Reprogramming a control unit.................................. 36
I S
Index....................................................................... 15 Safety Instructions.................................................... 13
SCR technology....................................................... 19
M
SCR Vodia log test................................................... 47
Main Components.................................................... 21
SCR Vodia tests....................................................... 40
Measurements................................................ 111, 135
SCR Warnings and Inducement................................. 7
MID 128, PID 354 Relative Humidity ....................... 54
Special Service Tools............................................... 17
MID 128, PID 51 Throttle Position.................... 48, 126
Specifications, Electrical........................................... 11
MID 128, PPID 270 NOx Sensor Gas Outlet ........... 56
MID 128, PPID 272 Air temperature for T
humidity compensation ............................................ 60 Technical Data................................................. 11, 125
MID 128, PPID 273 Aftertreatment Reagent W
Pressure................................................................... 62 Wiring Diagrams..................................................... 1
MID 128, PPID 274 After-treatment Reagent
Tank Temperature.................................................... 68
MID 128, PPID 275 After-treatment Reagent
Filter Temperature ................................................... 71
MID 128, PPID 278 After-treatment Reagent
Level ........................................................................ 74

47702556 02-2012 1

 References to Service Bulletins

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make a copy of this page, write down your views and send them to us.
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Refers to publication:...................................................................................................................................

Publication No.:....................................Date of issue:..................................................................................

Proposal/motivation:....................................................................................................................................

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Date:.....................................................................................

Signed:.................................................................................

AB Volvo Penta
Service Communication
Dept. 42200
SE-405 08 Göteborg
Sweden
47702556 English 02–2012