Workshop Manual I

Group 30 Electrical system 5(0)

TAD734GE, TAD550-551GE, TAD750-751GE,

TAD752-754GE, TAD560-561VE, TAD650VE,
TAD660VE, TAD750VE, TAD760VE, TAD761-765VE
37-0 Wiring Diagrams

Description TAD550-551 GE, TAD750-754

GE

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 = Grey
OR = Orange
6 Aux stop switch
P = Pink
7 Connector, Engine interface R = Red
SB = Black
8 Sensor, Coolant temperature
VO = Purple
9 Sensor, temperature/pressure, Charge Air W = White
Y = Yellow
10 Diagnosis connector, J1587
11 Cable cross section = 0.75 mm2 unless otherwise
stated.
12
13 Sensor, camshaft
14 Sensor, crankshaft
15
16 Injector
17 Relay, Preheater
18 Fuse
19 Fuse, 10 A
20 Preheater
21 Switch, Coolant Level
22
23 Switch, Water in Fuel
24 Oil pressure sensor
25 Fuel pressure sensor
26 Fuel/Rail Pressure
27
28
29
30 Control unit EMS 2
31
32 MPROP
33 Connector, Preheat relay
34 External EGR
35 Fuse 30A
36
37
38
39 Electric fan

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 37-0 Wiring Diagrams

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
11 SB
VO 7
41
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

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37-0 Wiring Diagrams

Description 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
11 Stop switch, spring biased Cable cross section = 0.75 mm2 unless otherwise
stated.
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 Horn
20 Operation indicator
21 Preheating indication
22 Preheating 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 protection override
29 Easy Link connector block
30 Control Interface Unit (CIU)

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 37-0 Wiring Diagrams

DCU

1 2 3 4 5 6 7 8 8

SB 2,5

BL 2,5
11

W/SB
GR/Y

R 2,5
Y/W

W
R/BL 1,5
1
Y/W

2
GR/W

SB 2,5
3

R 2,5
4

R/BL 2,5
5

6
BL 2,5

7
W

8 W/SB

R/BL 1,5
SB 2,5

BL 2,5

W/SB
3

GR/Y

R 2,5
Y/W

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

R/BL
4 5
1
Y
5 2
3
SB
6

GN/R
7

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

11
SB/GR

12
SB/W

P0014021

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

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

47702487 10-2016 © AB VOLVO PENTA

BATT.+ STOP 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
Wiring Diagram TAD560-561VE

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

162
1 - +
 37-0 Wiring Diagrams

Description for wiring diagram TAD560-561VE

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, pre-heating
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

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

47702487 10-2016 © AB VOLVO PENTA

BATT.+ STOP 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
Wiring Diagram TAD761-765VE

R/BL 1 W
5
86
23 Y/SB
1
85
2 1 R/BL 1,5 R/BL 1,5 87
2
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 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 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
CYL. 5 B+ B- SB 25

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

164
1 - +
16
 37-0 Wiring Diagrams

Description for wiring diagram

TAD761-765VE

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, pre-heating
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

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39-0 General

39-0 General
Index
MID 164: HCU
Caption SPN Flashcode / PID PPID SID PSID FMI
electrical
fault / value
fault
MID 128, PID 45 Inlet air heater
626 5.4/- 45 3, 4, 5
status, page 45
MID 128, PID 94 Fuel Delivery
94 3.6/3.8 94 1, 3, 5, 7
Pressure, page 47
MID 128, PID 97 Water in fuel
97 2.9/2.1 97 0, 4
indicator, page 51
MID 128, PID 100 Engine oil
100 3.1/6.6 100 1, 3, 5
pressure, page 53
MID 128, PID 105 Intake manifold
105 3.2/6.2 105 0, 4, 5
temperature, page 56
MID 128, PID 106 Air inlet
106 3.4/3.5 106 0, 3, 5
pressure, page 59
MID 128, PID 108 Barometric
108 -/- 108 2, 3, 4
pressure, page 62
MID 128, PID 110 Engine coolant
110 3.3/6.1 110 1, 3, 4
temperature, page 63
MID 128, PID 111 Coolant
111 2.3/2.2 111 1
level, page 66
MID 128, PID 158 ECU battery -/3.9 (EMS)
158 158 1
potential, page 68 -/6.9 (CIU)
MID 128, PID 164 Injection Control
164 8.3 164 0, 2, 4, 5
Pressure , page 69
MID 128, PID 190 Engine speed 190 -/2.6 190 0
MID 128 / 144, PPID 4 Starter input
4.7/5.2 4 3, 4
sensor, page 73
MID 128 / MID 144, PPID 6 Key off input 520195 4.8/- (EMS)
6 3, 4, 5
sensor, page 74 970 5.3/- (CIU)
MID 128, PPID 19 Internal EGR
8.5/- 19 3, 4, 5, 7
Status, page 76
MID 128, PPID 55 ECU temperature 8.4/- 55 0, 4, 5
MID 128, PPID 98 Engine sync
608 - 98 9
acknowledge, page 78
MID 128 / 144, PPID 132 Throttle
608 2.8/- 132 3, 4, 9
calibrated position, page 79
MID 128, SID 1/2/3/4/5/6 Injector # 651-65
7.1-7.6/- 1–6 3, 4, 5, 7, 12
1-6, page 81 6

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 39-0 General

Caption SPN Flashcode / PID PPID SID PSID FMI

electrical
fault / value
fault
MID 128, SID 21 Engine
636 2.5/- 21 2, 3, 8
position, page 85
MID 128, SID 22 Timing sensor,
637 2.4/- 22 2, 3, 8
crank, page 87
MID 128, SID 39 Engine Starter Motor 677/16
4.6 39 3, 4, 5
Relay , page 90 75
MID 128, SID 42 Fuel control
679 8.3/- 42 3, 4, 5, 6, 13
unit, page 93
MID 128, SID 70 Air inlet heater driver
729 70 3, 4, 5
#1, page 96
MID 128, SID 146 EGR Valve
2791 146 0, 2,4,7,12,13
1, page 98
MID 128, SID 211 Sensor Supply Voltage
9.3/- 211 3, 4
#2 (+5V DC), page 101
MID 128 / 144, SID 231 SAE J1939 data 6.5/- (EMS)
639 231 2
link, page 102 6.4/- (CIU)
MID 128, SID 232 5 V supply, page 104 620 9.3/- 232 3, 4
MID 128, SID 240 Program
639 9.9/- 240 2, 7, 11, 14
memory, page 105
MID 128 / MID 144, SID 250 SAE J1708/
608 9.2/- (EMS) 250 11
J1587 data link, page 106
MID 128, SID 254 Controller 9.9/- (EMS)
629 254 3, 8, 12
1, page 107 9.8/- (CIU)
MID 128, PSID 96 Rail pressure
1239 96 0, 1, 4, 7, 12
system, page 108
MID 128, PSID 97 Pressure Release
679 8.3 97 0, 7, 11, 14
Valve, page 113
MID 128, PSID 201 Data link, 639/16
- 201 9
MID144, page 115 75

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Index
A Concerned engines.................................................... 2
About this Workshop manual..................................... 2 D
C Design and Function................................................ 16
Changing the engine control unit.............................. 33 E
Checking air inlet pressure sensor......................... 127 Electrical System........................................................ 5
Checking camshaft sensor..................................... 135 Electrical Welding..................................................... 32
Checking camshaft sensor wiring........................... 134 EMS 2 (Engine Management System)..................... 16
Checking coolant level switch................................ 129 Engine Protection Map............................................... 7
Checking coolant temperature sensor.................... 143 F
Checking crankshaft sensor................................... 137 Fault Codes.............................................................. 45
Checking crankshaft sensor wiring......................... 136 Fault Tracing............................................................ 43
Checking fuel pressure sensor............................... 119 Fault tracing of cables and connectors..................... 43
Checking IEGR coil................................................ 132
Checking IEGR solenoid........................................ 132 G
Checking injection control pressure sensor............ 146 General................................................... 2, 16, 43, 166
Checking intake manifold temperature sensor....... 126 General advice......................................................... 42
Checking negative cable, coolant level switch....... 128 I
Checking negative cable, coolant temperature Index....................................................................... 166
sensor..................................................................... 140
L
Checking negative cable, fuel sensor..................... 118
Logging throttle signal with Vodia........................... 150
Checking negative cable, intake manifold
pressure/temperature sensor................................. 124 M
Checking negative cable, oil pressure sensor........ 122 Malfunctions............................................................. 40
Checking negative cable, rail pressure sensor....... 144 Manual fault tracing in bus cables............................ 39
Checking negative cable, water in fuel switch........ 120 MID 128 / 144, PPID 132 Throttle calibrated position 79
Checking oil pressure sensor................................. 123 MID 128 / 144, PPID 4 Starter input sensor............. 73
Checking sensor cable, coolant temperature MID 128 / 144, SID 231 SAE J1939 data link........ 102
sensor..................................................................... 142 MID 128 / MID 144, PPID 6 Key off input sensor..... 74
Checking sensor cable, intake manifold MID 128 / MID 144, SID 250 SAE J1708/J1587
temperature sensor................................................ 125 data link.................................................................. 106
Checking signal cable, coolant temperature sensor 141 MID 128, PID 100 Engine oil pressure..................... 53
Checking signal cable, fuel sensor......................... 119 MID 128, PID 105 Intake manifold temperature....... 56
Checking signal cable, intake manifold MID 128, PID 106 Air inlet pressure......................... 59
pressure sensor...................................................... 127 MID 128, PID 108 Barometric pressure................... 62
Checking signal cable, intake manifold MID 128, PID 110 Engine coolant temperature........ 63
temperature sensor................................................ 123 MID 128, PID 111 Coolant level............................... 66
Checking signal cable, oil pressure sensor............ 122 MID 128, PID 158 ECU battery potential.................. 68
Checking signal cable, rail pressure sensor........... 145 MID 128, PID 164 Injection Control Pressure ......... 69
Checking starter motor relay coil............................ 130 MID 128, PID 45 Inlet air heater status.................... 45
Checking starter motor relay voltage supply.......... 130 MID 128, PID 94 Fuel Delivery Pressure................. 47
Checking supply cable, coolant level switch.......... 128 MID 128, PID 97 Water in fuel indicator................... 51
Checking supply cable, fuel sensor........................ 117 MID 128, PPID 19 Internal EGR Status................... 76
Checking supply cable, intake manifold MID 128, PPID 98 Engine sync acknowledge.......... 78
pressure sensor...................................................... 126 MID 128, PSID 201 Data link, MID144................... 115
Checking supply cable, oil pressure sensor........... 121 MID 128, PSID 96 Rail pressure system................ 108
Checking supply cable, rail pressure sensor.......... 144 MID 128, PSID 97 Pressure Release Valve........... 113
Checking supply cable, water in fuel switch........... 120 MID 128, SID 1/2/3/4/5/6 Injector # 1-6.................... 81
Checking the CAN bus cable......................... 138, 139 MID 128, SID 146 EGR Valve 1............................... 98
Checking the charging system................................. 37 MID 128, SID 21 Engine position............................. 85
Checking the coolant level..................................... 150 MID 128, SID 211 Sensor Supply Voltage #2
Checking the injectors............................................ 133 (+5V DC)................................................................ 101
Checking the preheat relay.................................... 117 MID 128, SID 22 Timing sensor, crank.................... 87
Checking the solenoid in the MPROP valve........... 148 MID 128, SID 232 5 V supply................................. 104
Checking the starter motor voltage.......................... 36 MID 128, SID 240 Program memory...................... 105
Checking the wiring................................................ 131 MID 128, SID 254 Controller 1............................... 107
Checking the wiring to the MPROP valve.............. 147 MID 128, SID 39 Engine Starter Motor Relay ......... 90
Checking water in fuel switch................................. 121 MID 128, SID 42 Fuel control unit............................ 93
Component description............................................ 26 MID 128, SID 70 Air inlet heater driver #1................ 96
Component location................................................. 19

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O
Other Special Equipment......................................... 15
P
Programming an empty control unit......................... 35
R
Rail pressure measurement..................................... 38
Repair Instructions................................................... 32
Repair instructions...................................................... 3
Reprogramming a control unit.................................. 34
S
Safety Information.................................................... 10
Safety Instructions.................................................... 10
Special Service Tools............................................... 14
Specifications, Electrical............................................. 5
T
Technical Data........................................................... 5
V
VODIA Log Parameters.......................................... 150
W
Wiring Diagrams..................................................... 151

170 47702487 10-2016 © AB VOLVO PENTA

 References to Service Bulletins

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

AB Volvo Penta
Service Communication
Dept. 42200
SE-405 08 Göteborg
Sweden
47702487 English 10–2016