Content

Safety rules

General information

• About this workshop manual
• Spare parts
• Certified engines

Repair instructions

• Our common responsibility
• Tightening torques

Special tools

EMS 2 - “Engine Management System”

• General information
• CAN - controller area network
• CIU - control interface unit
• DCU - display control unit
• Fuel control
• Calculation of fuel quantity
• Altitude correction
• Diagnostic function

Component location

• TAD 650, 660, 750, 760 VE
• TAD 734 GE

Component description

• Starter motor
• Alternator
• Injectors
• Speed sensor, crankshaft
• Speed sensor, camshaft
• Sensor, boost pressure / boost temperature
• Sensor, oil pressure, engine
• EGR
• Coolant temperature sensor
• Sensor, common rail pressure (fuel)
• Sensor, fuel pressure
• Magnetically controlled proportional valve (MPROP)
• Water in fuel switch, secondary fuel filter
• Switch, coolant level
• Preheater
• Engine control unit, EMS 2

Repair instructions

• General advice on working with EMS engines
• Electric welding
• Changing the engine control unit
• Reprogramming a control unit
• Programming an empty control unit
• Fault tracing of cables and connectors
• Checking the starter motor voltage
• Checking the charging system
• Rail pressure measurement

Malfunctions

• Fault code information
• FMI table / SAE standard
• Manual fault tracing in bus cables

Diagnostic trouble codes

• MID 128, PID 100 Oil pressure
• MID 128, PID 97 Water in fuel
• MID 128, PID 94 Fuel pressure
• MID 128, PID 45 Inlet air heater status
• MID 128, PID 105 Boost temperature
• MID 128, PID 106 Boost pressure
• MID 128, PID 108 Ambient air pressure
• MID 128, PID 110 Coolant temperature
• MID 128, PID 111 Coolant level
• MID 128, PID 158 Battery voltage
• MID 128, PID 164 Rail pressure
• MID 128, PID 190 Engine speed
• MID 128 / MID 144, PPID 4 Start input CIU
• MID 128 / MID 144, PPID 6 Engine stop switch
• MID 128, PPID 19 Internal EGR status
• MID 128, PPID 55 EMS temperature
• MID 128, PPID 98 Engine sync acknowledge
• MID 128 / 144, PPID 132 Throttle input request failure, DCU/CIU
• MID 128, SID 1-6 Injector common rail
• MID 128, SID 21 Speed sensor camshaft
• MID 128, SID 22 Speed sensor, crankshaft
• MID 128, SID 39 Engine starter relay
• MID 128, SID 42 Injection control pressure regulator
• MID 128, SID 70 Preheat sense
• MID 128, SID 211 5V sensor supply 2
• MID 128, SID 231 Communication fault J 1939
• MID 128, SID 232 5V sensor supply 1
• MID 128, SID 240 Program memory
• MID 128, SID 254 Controller error
• MID 128, PSID 96 Rail pressure system
• MID 128, PSID 97 Rail pressure release valve
• MID 128 / MID 144, PSID 201 J1939 communication bus

Engine protection

• TAD 650, 660, 750, 760 VE
• TAD 734 GE

Wiring diagrams

• Wiring diagram EMS 2
• Vechicle harness TAD 650-760VE
• Engine harness TAD 650-760VE
• Engine harness TAD 734GE
• Wiring diagram DCU
• Wiring diagram CIU

Technical data

• Switch, water in fuel
• Sensor, fuel pressure
• Speed sensor, camshaft / speed sensor, crankshaft
• Sensor, oil pressure
• Sensor, rail pressure
• Combination sensor, boost pressure / boost temperature
• Sensor, coolant temperature
• Switch, coolant level
• Alternator
• Starter motor

Index