Service Information

Document Title: Function Group: Information Type: Date:

Service Information 5/14/2015
Profile:

Diagnostics
WARNING
Please pay attention to the safety instructions in the Operator's and Service Manuals concerned.

The purpose of the diagnostic function is a guide for use with other troubleshooting tools. Diagnostics should help the service
technician to find and choose the correct tests and tools. Furthermore it should suggest the order to use them. The intention of
diagnostics is thought to be a complement to the skills and judgment of the service technician.
General fault diagnosis information:
Troubleshooting strategy
During fault tracing, always remember to document all measurement test results.
Remember to check recent service bulletins for related issues
Use the drop-down menus to the left to match the current fault mode with suitable diagnostic information.
ISO Code is used for vehicle messages extracted with Tech Tool, vehicle messages displayed to the operator, or retrieved from
the Care Track System.
ISO codes are introduced for some machines in compliance with emission requirements for US Tier 4 Final and EU Stage IV.
Example: P012300
SAE Code is used for vehicle messages extracted with Tech Tool, or retrieved from the Care Track System
Example: PID 27
MDT (Machine Display Text) is used for vehicle messages viewed in the machine display.
Example: SE2501–1
Sym (Symptom) is used for fault tracing of an abnormal behavior of a specific machine system.
New diagnostic layout for machines using ISO-codes:

Failure event Describing what has happened. What is wrong.

Symptom Describing symptoms associated with the error code.
Conditions Describing some conditions that needs to be fulfilled for the error code to be produced.
Inhibiting the DTC List of error codes that are inhibiting the error code (DTC).
Possible causes List of possible causes.
Action List of suggested actions including links to methods and Tech Tool operations. Links to decision trees are
also provided, when required. (Decision trees are selectable using the button in the bottom right corner.)
Go back to Index Page

Troubleshooting strategy
The starting point for all troubleshooting is some type of problem, symptom or malfunction being noticed. The strategy and procedure
for troubleshooting is described in the following flow chart.

Start

Collection of basic data. See "Collection of basic data".

Read-out of error codes. Error codes found?

YES
NO

Note error codes.

Troubleshoot using the "Error code, troubleshooting".

Solve / repair the malfunction.

Activate the component or function in question.

Read-out of error codes. Problem solved?

YES NO
OK Check parameters. See "Parameters". Are parameters set incorrectly?
YES
NO
Reprogram parameters. Problem solved?
YES NO

OK Perform basic check. See section 2 (engine). Problem identified?

YES
NO
Go to checklist for the symptom. Problem solved?
YES NO

OK Troubleshoot using symptoms. See "Troubleshooting using symptoms". Problem

identified?

YES
NO
Go to checklists for the symptom.
Problem solved?
YES NO
OK Check performance (only for engine). See section 2. Problem
solved?
YES NO
OK Troubleshoot using other information.[ 1]

The following describes the included steps in the troubleshooting strategy.

NOTE!
If new or reappearing error codes are generated during troubleshooting, take appropriate action to repair, etc. before continuing to
troubleshooting.

1. The basis for all troubleshooting is some type of symptom or malfunction. In order to arrive at a basis for troubleshooting, a
collection of data concentrated around the symptom/function disruption should be done.
A checklist for collecting this data is also available in the form of " Collection of basis data".
2. The error codes give a clear indication of what has caused the symptom or malfunction. Therefore, read out error codes
before any troubleshooting is started.
Check if there are any error codes generated in the machine’s control units. The error codes can be read from the contronics
service display unit or using VCADS Pro.

A. If an error code has been generated, troubleshooting should be performed according to the reference from "Error
 code, troubleshooting".
B. The existing error codes are noted and then compared to any new or reappearing error code. When the problem has
been solved, the error codes should be erased.
C. In order to confirm that the malfunction has been corrected, the machine components/functions in question must be
activated so that the control unit can perform a new self-diagnosis, and generate eventual new or reappearing error
codes.
D. The error codes are read to confirm that the symptom/malfunction has been corrected and to make sure that no
subsequent problems have occurred in connection with repair work.

3. Check that the parameters are set correctly. A list of all parameters and parameter values are found in the form of a
parameter list.
4. The basic check is divided into three tests, which should be performed in the order that they are presented. See section 2,
Basic check engine.

[ 1]See the wiring diagrams, component troubleshooting and troubleshooting using symptoms.
 Volvo Guided Diagnostics

Date: Information Type:

5/14/2015 Diagnostics Fault Codes 128: Engine ECU 100: Engine oil pressure
Profile:
EXC, EC210B LC Volvo [GB] EXC, EC210B LC Volvo [GB] EXC, EC210B LC Volvo [GB] EXC, EC210B LC Volvo [GB] EXC,
EC210B LC Volvo [GB]

MID128 PID100 / 128 PID100

SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PID100 Engine oil pressure
Machine display message
Text presentation 128 PID100

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above
FMI 3 4.75 V (EB11)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to higher

Buzzer sounds one time voltage

Error message screen
Open circuit on frame ground cable

Defective sensor

Action 128 PID100

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below
FMI 5 0.25 V (EB11)
Symptom: Possible causes:

Red central warning
Signal line contains a short circuit

Buzzer sounds one time to a lower voltage

Error message screen
Open circuit on feed cable

Open circuit on signal line

Defective sensor

Action 128 PID100

Guided Diagnostics
Go back to Index Page

128 PID100
Description and measuring

SE2203 Engine oil pressure sensor

Function Detects low engine oil pressure
Wiring diagram
VCADS Pro See test 28407-3 Sensor values, monitoring

EA5, frame ground

EA14, oil pressure signal
EA4, supply (5 V)
Control unit/ Frame ground
cable harness: cable 4 ≈0Ω
- Frame ground

1) 2) 3) 4)
Supply cable 1
- Frame ground ≈5V

1) 2) 3)
Signal line 2
- Frame ground ≈ 100 KΩ

1) 2) 3) 4)
Specific part of 2 - 4 ≈ 0.5 V
system: (engine
stationary)

1) 2) 3)
 Volvo Guided Diagnostics

Date: Information Type:

5/14/2015 Diagnostics Fault Codes 128: Engine ECU 102: Boost pressure
Profile:
EXC, EC210B LC Volvo [GB] EXC, EC210B LC Volvo [GB] EXC, EC210B LC Volvo [GB] EXC, EC210B LC Volvo [GB] EXC,
EC210B LC Volvo [GB]

MID128 PID102 / 128 PID102

SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PID102 Boost pressure
Machine display message
Text presentation 128 PID102

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Boost pressure higher than
FMI 0 240 kPa
Symptom: Possible causes:

Red central warning
Wastegate stuck

Buzzer sounds continuously
Defective sensor

Error message screen

Action VCADS Pro, Test

28407-3 Sensor values, monitoring
Check that the wastegate is not stuck by checking the movement of the wastegate linkage
when stalling the engine

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above
FMI 3 4.95 V (EA22)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to higher

Buzzer sounds continuously voltage

Error message screen
Open circuit on frame ground cable

Low power
Defective sensor

Action 128 PID102

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below
FMI 5 0.12 V(EA22)
Symptom: Possible causes:

Red central warning
Open circuit on feed cable

Buzzer sounds continuously
Signal line contains a short circuit

Error message screen to a lower voltage

Low power
Open circuit on signal line

Defective sensor

Action 128 PID102

Guided Diagnostics
Go back to Index Page

128 PID102
Description and measuring

SE2508 Charge-air (Boost) pressure sensor

Function Measures charged-air (boost) pressure (combined
sensor).
Wiring
diagram
VCADS Pro See test 28407-3 Sensor values, monitoring
EA5, frame ground
EA3, charge-air pressure signal
EA4, supply (5 V)
Control unit/ Frame ground
cable harness: cable 4 ≈0Ω
- Frame ground

1) 2) 3) 4)
Supply cable 1
- Frame ground ≈5V

1) 2) 3)
Signal line 2
- Frame ground ≈ 100 KΩ

1) 2) 3) 4)
Specific part of 2 - 4 ≈ 1.1 V
system: (engine
stationary)

1) 2) 3)
 Volvo Guided Diagnostics

Date: Information Type:

5/14/2015 Diagnostics Fault Codes 128: Engine ECU 105: Intake manifold temperature
Profile:
EXC, EC210B LC Volvo [GB] EXC, EC210B LC Volvo [GB] EXC, EC210B LC Volvo [GB] EXC, EC210B LC Volvo [GB] EXC,
EC210B LC Volvo [GB]

MID128 PID105 / 128 PID105

SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PID105 Intake manifold temperature
Machine display message
Text presentation 128 PID105

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Boost temperature higher
FMI 0 than 90ºC
Symptom: Possible causes:

Red central warning
Poor cooling

Buzzer sounds one time
Extreme running conditions

Error message screen
Defective sensor

Action Cooling system, inspection

Turbocharger, inspection
128 PID105

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Boost temperature higher
FMI 0 than 92ºC
Symptom: Possible causes:

Red central warning
Poor cooling

Buzzer sounds continuously
Extreme running conditions

Error message screen
Defective sensor

Low power because of engine
protection

Action Cooling system, inspection

Turbocharger, inspection
128 PID105

Fault mode Detection conditions:The engine control unit (E-ECU) registers: the value difference
FMI 2 between the boost temperature and the air inlet temperature or coolant temperature is out
of range
Symptom: Possible causes:

Red central warning
Defective boost temperature sensor

Buzzer sounds one time
Defective air inlet temperature

Error message screen sensor

Low power because of engine
Defective sensor Engine coolant
protection temperature

Connector problems

Wire harness problems

Action Monitor and log the sensor value to find out the wrong value.
128 PID105
128 PID172
128 PID110

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below
FMI 4 0.02 V(EA47)
Symptom: Possible causes:

Red central warning
Signal line contains a short circuit

Buzzer sounds one time to a lower voltage

Error message screen
Defective sensor

Engine can be difficult to start in
cold climate

Action 128 PID105

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above
FMI 5 4.5 V (EA47)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to higher

Buzzer sounds one time voltage

Error message screen
open circuit

Engine can be difficult to start in
Defective sensor
cold climate

Action 128 PID105

Guided Diagnostics
Go back to Index Page

128 PID105
Description and measuring

SE2507 Charge-air (Boost) temperature sensor

Function Measures charged-air (boost) temperature (combined
sensor).
Wiring
diagram
VCADS Pro See test 28407-3 Sensor values, monitoring
EA5, frame ground
EA2, charge-air temperature signal
Control unit/ Frame ground
cable cable 4 ≈0Ω
harness: - Frame ground

1) 2) 3) 4)
Signal line 3
- Frame ground ≈ 5.7 KΩ

1) 2) 3)
Specific part 3 - 4 See table
of system: below

1) 2) 3) 4)

Sensor specification

Air temperature, ºC (ºF) Resistance Air temperature, ºC (ºF) Resistance

–40 (–40) 168 ± 13 kΩ +60 (140) 1240 ± 42 Ω
–30 (–22) 88 ± 6 kΩ +70 (158) 873 ± 33 Ω
–20 (–4) 48 ± 3 kΩ +80 (176) 627 ± 26 Ω
–10 (–14) 27 ± 2 kΩ +90 (194) 458 ± 20 Ω
0 (32) 16 ± 1 kΩ +100 (212) 339 ± 15 Ω
+10 (50) 9.9 ± 0.5 kΩ +110 (230) 255 ± 12 Ω
+20 (68) 6.2 ± 0.3 kΩ +120 (248) 195 ± 10 Ω
+30 (86) 4.0 ± 0.2 Ω +130 (266) 150 ± 8 Ω
+40 (104) 2648 ± 97 Ω +140 (284) 117 ± 7 Ω
+50 (122 1793 ± 58 Ω +150 (302) 93 ± 6 Ω
MID128 PID110 / 128 PID110
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PID110 Engine coolant temperature
Machine display message
Text presentation 128 PID110

Reference Cooling system, description

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Coolant temperature higher
FMI 0 than 100ºC
Symptom: Possible causes:

Red central warning
Low coolant level

Buzzer sounds continuously
Clogged radiator

Error message screen
Wrong coolant

Extreme running conditions

Action 128 PID110

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below
FMI 4 0.12 V(EB27)
Symptom: Possible causes:

Red central warning
Signal line contains a short circuit to a

Buzzer sounds continuously lower voltage

Error message screen
Defective sensor

Action 128 PID110

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above
FMI 5 4.92 V(EB27)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to higher

Buzzer sounds continuously voltage

Error message screen
open circuit

Defective sensor

Action 128 PID110

Guided Diagnostics
Go back to Index Page

128 PID110
Description and measuring

SE2606 Engine coolant temperature sensor

Function Senses coolant temperature in engine.
Wiring diagram
VCADS Pro See test 28407-3 Sensor values, monitoring

EA25, signal line

EA5, frame ground
Control unit/ Frame ground cable
cable harness: 2 ≈0Ω
- Frame ground

1) 2) 3) 4)
Signal line 1
- Frame ground ≈ 1.4 KΩ

1) 2) 3) 4)
Supply cable 1
- Frame ground ≈5V

1) 2) 3)
Specific part of 1–2 See table below
system:

1) 2) 3) 4)

Sensor specification

Air temperature, ºC (ºF) Resistance Air temperature, ºC (ºF) Resistance

–30 (–22) 27.5 ± 3.2 kΩ +60 (140) 376 ± 20 Ω
–20 (–4) 15.0 ± 1.6 kΩ +70 (158) 267 ± 13 Ω
–10 (–14) 8.5 ± 0.82 kΩ +80 (176) 191.1 ± 8.5 Ω
0 (32) 4.9 ± 0.44 kΩ +90 (194) 139.7 ± 8.5 Ω
+10 (50) 3.0 ± 0.25 kΩ +100 (212) 103.7 ± 3.7 Ω
+20 (68) 1.9 ± 0.14 kΩ +110 (230) 78.0 ± 2.8 Ω
+30 (86) 1205 ± 85 Ω +120 (248) 59.5 ± 2.4 Ω
+40 (104) 798 ± 52 Ω +130 (266) 45.9 ± 2.0Ω
+50 (122 542 ± 32 Ω
Go back to Index Page

Cooling system, description

SN: 35001 ~ 110000
The cooling unit cells and tanks are made of aluminium. The hydraulic oil cooler and the charge air cooler are installed to the radiator
frame.
Air is drawn into the engine compartment passing through the radiator, the oil cooler and the charge air cooler as the fan rotates.

Figure 1
Cooling unit

1 Coolant inlet 7 Hydraulic oil cooler

2 Charge air inlet 8 Radiator drain plug
3 Charge air outlet 9 Radiator
4 Coolant outlet 10 Charge air cooler
5 Hydraulic oil outlet 11 Hydraulic oil cooler drain plug
6 Hydraulic oil inlet
MID128 PID164 / 128 PID164
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PID164 Injection Control Pressure
Machine display message
Text presentation 128 PID164

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: too high pressure(EA19)
FMI 0 Symptom: Possible causes:

Red central warning
Signal line short-circuited to higher

Buzzer sounds continuously voltage

Error message screen
Open circuit on signal line

Also sets MID 128 PSID 97 FMI 14
Open circuit on feed cable

Max. speed is limited to 1100 rpm by
Open circuit on frame ground cable
the engine protection function
Defective fuel system

Low power because of engine
Defective sensor
protection

Rail pressure limitation

Engine shutdown

Action MID 128 PID 164 Injection control pressure

Fuel system, check

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Too low pressure(EA19)
FMI 1 Symptom: Possible causes:

Red central warning
Signal line contains a short circuit to a

Buzzer sounds continuously lower voltage

Error message screen
Defective fuel system

Also sets MID 128 PSID 97 FMI 14
Defective sensor

Max. speed is limited to 1100 rpm by
the engine protection function

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 PID 164 Injection control pressure

Fuel system, check
Check the Fuel system for leakage, especially the high pressure side.

Fault mode Detection conditions:The engine control unit (E-ECU) registers: unreasonable measuring
FMI 2 value (EA19)
Symptom: Possible causes:

Red central warning
Voltage feed for sensors

Buzzer sounds continuously
Contact resistance in connectors

Error message screen
Defective fuel system

Also sets MID 128 PSID 97 FMI 14
Defective sensor

Max. speed is limited to 1100 rpm by
the engine protection function

Low power because of engine
protection

Rail pressure limitation

Engine shutdown
Action MID 128 PID 164 Injection control pressure
Fuel system, check
Check the Fuel system for leakage, especially the high pressure side.

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below 0.2
FMI 4 V (EA19)
Symptom: Possible causes:

Red central warning
Signal line contains a short circuit to a

Buzzer sounds continuously lower voltage

Error message screen
Contact resistance in connectors

Also sets MID 128 PSID 97 FMI 14
Defective sensor

Max. speed is limited to 1100 rpm by
the engine protection function Low
power because of engine protection

Rail pressure limitation

Engine shutdown

Action MID 128 PID 164 Injection control pressure

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above 4.8
FMI 5 V (EA19)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to higher

Buzzer sounds continuously voltage

Error message screen
Open circuit on signal line

Also sets MID 128 PSID 97 FMI 14
Open circuit on feed cable

Max. speed is limited to 1100 rpm by
Open circuit on frame ground cable
the engine protection function
Defective sensor

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 PID 164 Injection control pressure

Guided Diagnostics
MID 128 PID 164 Injection control pressure
Description and measuring

SE2309 Sensor, common rail pressure

Function Measures the fuel pressure in the common rail.
Wiring diagram
Installing/ Tightening torque:
Adjusting: VCADS Pro:

Control unit/ ≈0Ω

cable harness: 1–

≈5V
3–

A19–2 ≈0Ω

Component: ≈∞Ω
1–

3–
A19–A11 ≈ 0.5 V
MID128 PID45 / 128 PID45
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PID45 Inlet air heater status
Machine display message
Text presentation 128 PID45

Reference Preheating, description

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the current is above 3.9
FMI 3 A(EB25)
Symptom: Possible causes:

Red central warning
Signal line between relay and E-ECU

Buzzer sounds one time short-circuited to Ubat

Error message screen
Defective relay

Preheating not functioning

White smoke during cold starts

Difficult to start in extreme cold

Action 128 PID45

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below
FMI 4 0.33xUbat(EB25)
Symptom: Possible causes:

Red central warning
Short circuit to lower voltage

Buzzer sounds continuously
Defective relay

Error message screen

Induction air is warm due to
continuously activated relay

Action 128 PID45

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above
FMI 5 0.33xUbat and below 0.66xUbat (EB25)
Symptom: Possible causes:

Red central warning
Defective fuse for feed voltage to relay

Buzzer sounds one time
Open circuit on cable between E-ECU

Error message screen and relay

Preheating not functioning
Open circuit in relay

White smoke during cold starts
Open circuit on feed cable to relay

Difficult to start in extreme cold
Defective relay

Action 128 PID45

Guided Diagnostics
Go back to Index Page

128 PID45
Description and measuring

RE2501 Induction air preheating relay

Function Activates the preheating coil.
Wiring diagram
VCADS Pro

EB5, diagnostic signal

EB31, preheating relay signal
Control unit/ Control cable 86 ≈ U ᵇᵃᵗ (relay not
cable harness: - Frame ground activated)
≈ 0 V (relay
activated)
1) 2) 3)
Supply cable 85
- Frame ground ≈ U ᵇᵃᵗ

1) 2) 3)
Supply cable 30
- Frame ground ≈ U ᵇᵃᵗ

1) 2) 3)
Component: (a) 85 - 86 ≈ 30 Ω

1) 2) 3) 4)
Specific part of EB5 - EB9 ≈ 0.55 x U ᵇᵃᵗ
system (b) (closed circuit)
≈ 0 V (open
circuit)
1) 2) 3)

≈ U ᵇᵃᵗ (relay not

EB31 - EB9 activated)
≈ 0 V (relay
activated)

a. Blue/red cable to relay disconnected (cable goes towards control unit).

b. Blue/red cable and black cable connected to relay on respective connections.
MID128 PID94 / 128 PID94
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PID94 Fuel feed pressure
Machine display message
Text presentation 128 PID94

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Fuel feed pressure below
FMI 1 static min value
Symptom: Possible causes:

Red central warning
Clogged fuel filter

Buzzer sounds continuously
Clogged fuel supply lines

Error message screen
Contaminated fuel tank

Fuel injection can be affected
Contaminated fuel

Can cause low rail pressure
Defective fuel pump

Low power
Air or leakage in fuel system

Engine difficult to start
Defective sensor

Action 128 PID94

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above
FMI 3 4.75 V (EB16)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to higher

Buzzer sounds continuously voltage

Error message screen
Open circuit on frame ground cable

Defective sensor

Action 128 PID94

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below
FMI 5 0.25 V (EB16)
Symptom: Possible causes:

Red central warning
Signal line contains a short circuit to a

Buzzer sounds continuously lower voltage

Error message screen
Open circuit on feed cable

Open circuit on signal line

Defective sensor

Action 128 PID94

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Fuel feed pressure below
FMI 7 engine speed dependent min value
Symptom: Possible causes:

Red central warning
Clogged fuel filter

Buzzer sounds continuously
Clogged fuel supply lines

Error message screen
Contaminated fuel tank

Fuel injection can be affected
Contaminated fuel

Can cause low rail pressure
Defective fuel pump

Low power
Air or leakage in fuel system

Engine difficult to start
Defective sensor
Action 128 PID94

Guided Diagnostics
128 PID94
Description and measuring

SE2301 Fuel pressure sensor

Function Defects fuel pressure of engine
Wiring diagram
VCADS Pro See test 28407-3 Sensor values, monitoring

EB18, frame ground

EB16, fuel pressure signal
EB17, supply (5 V)
Control unit/cable Frame ground cable
harness: 4 ≈0Ω
- Frame ground

1) 2) 3) 4)
Supply cable 1
- Frame ground ≈5V

1) 2) 3)
Signal line 2
- Frame ground ≈ 100 KΩ

1) 2) 3) 4)
Specific part of 2 - 4 ≈ 0.5 V (engine
system: stationary)

1) 2) 3)
MID128 PID97 / 128 PID97
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PID97 Water in fuel indicator
Machine display message
Text presentation 128 PID97

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below
FMI 0 0.75xUbat (EB8)
Symptom: Possible causes:

Red central warning
Water in fuel

Buzzer sounds one time
Defective sensor

Error message screen

Action Drain water in fuel See Operator's Manual.

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above
FMI 3 0.91xUbat (EB8)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to higher

Buzzer sounds one time voltage

Error message screen
Defective sensor

Action 128 PID97

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below
FMI 4 0.05xUbat (EB8)
Symptom: Possible causes:

Red central warning
Signal line contains a short circuit to a

Buzzer sounds one time lower voltage

Error message screen
Defective sensor

Action 128 PID97

Guided Diagnostics
128 PID97
Description and measuring

SE2302 Water in fuel sensor

Function Detects high water level of separator.
Wiring diagram
VCADS Pro See test 28407-3 Sensor values, monitoring

EB8, signal line

EB10, frame ground
Control unit/cable Frame ground cable
harness: 2 ≈0Ω
- Frame ground

1) 2) 3) 4)
Signal line 1 - EB8
≈0Ω

1) 2) 3) 4)
Component 1-2
≈ ∞ Ω (normal
level)
≈ 0 Ω (low
level) 1) 2) 3) 4)
MID128 PID98 / 128 PID98
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PID98 Engine oil level
Machine display message
Text presentation 128 PID98

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: low engine oil level (only
FMI 1 detected when the engine is not running)
Symptom: Possible causes:

Red central warning
Low engine oil level

Buzzer sounds continuously
Internal leakage

Error message screen
Oil leakage from engine

Defective sensor

Action Check engine oil level

Check the sensor for mechanical damages and cracks
128 PID98
Check for external and internal leakage

Fault mode Detection conditions:The engine control unit (E-ECU) registers: voltage too low (EB4/EB3)
FMI 4 Symptom: Possible causes:

Red central warning
Signal line short-circuited to frame

Buzzer sounds continuously ground

Error message screen
Defective sensor

Action 128 PID98

Fault mode Detection conditions:The engine control unit (E-ECU) registers: current too low (EB4/EB3)
FMI 5 Symptom: Possible causes:

Red central warning
Open circuit on signal line

Buzzer sounds continuously
Open circuit on ground line

Error message screen
Signal line short-circuited to higher
voltage

Loose connection

Defective sensor

Action 128 PID98

Guided Diagnostics
128 PID98
Description and measuring

SE2205 Engine oil level sensor

Function Detects low oil level of engine
Wiring diagram
VCADS Pro See test 28407-3 Sensor values, monitoring

EB4, signal line

EB3, frame ground
Control unit/cable 1 - Frame ground
harness: - Frame ground ≈ 3 MΩ

1) 2) 3) 4)
2 - Frame ground
≈ 2 ~ 4.5 V

1) 2) 3)
Component 1-2
≈ ∞ Ω (normal
level)
≈ 0 Ω (low
level) 1) 2) 3) 4)
MID128 PSID96 / 128 PSID96
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PSID96 Rail pressure system
Machine display message
Text presentation 128 PSID96

Reference Fuel system, description

Fuel control valve (FCV), description
Injectors, description

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the rail pressure control
FMI 0 is not working correctly
Symptom: Possible causes:

Red central warning
Defective fuel control valve.

Buzzer sounds continuously
Defective rail pressure sensor

Error message screen
Defective injectors

Full fuel flow delivery

Max. speed is limited to 1100 rpm by
the engine protection function

Also sets MID 128 PSID 97 FMI 14

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 SID 42 Fuel control unit

Fuel rail pressure, checking

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the rail pressure control
FMI 1 is not working correctly
Symptom: Possible causes:

Red central warning
Defective fuel control valve.

Buzzer sounds continuously
Defective rail pressure sensor

Error message screen
Defective injectors

Max. speed is limited to 1100 rpm by
Pressure relief valve locked in open
the engine protection function position

Also sets MID 128 PSID 97 FMI 14
High pressure leakage

Low power because of engine
Low pressure circuit
protection

Rail pressure limitation

Engine shutdown

Action MID 128 SID 42 Fuel control unit

Fuel rail pressure, checking

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Low rail pressure
FMI 4 Symptom: Possible causes:

Red central warning
Defective fuel control valve.

Buzzer sounds continuously
Air in fuel system

Error message screen
Defective injectors

Max. speed is limited to 1100 rpm by
Pressure relief valve locked in open
the engine protection function position

Also sets MID 128 PSID 97 FMI 14
High pressure leakage

Low power because of engine
Low pressure circuit
protection
Defective rail pressure sensor

Rail pressure limitation

Engine shutdown

Action MID 128 PID 164 Injection control pressure

MID 128 SID 42 Fuel control unit
Fuel rail pressure, checking

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the rail pressure control
FMI 12 is not working correctly
Symptom: Possible causes:

Red central warning
Defective fuel control valve.

Buzzer sounds continuously
Defective injectors

Error message screen
Pressure relief valve unwanted

Max. speed is limited to 1100 rpm by opening
the engine protection function
High pressure leakage

Also sets MID 128 PSID 97 FMI 14
Low pressure circuit

Low power because of engine
Defective rail pressure sensor
protection

Rail pressure limitation

Engine shutdown

Action MID 128 PID 164 Injection control pressure

MID 128 SID 42 Fuel control unit
Fuel rail pressure, checking

Guided Diagnostics
Go back to Index Page

Fuel system, description

General
The engine has an injection system where the fuel is injected into the combustion chambers via separate injection
pumps one for each cylinder.
The fuel is delivered from the tank via the primary filter by the fuel feed pump via the secondary filter to the supply
channel for the unit pumps.
From the unit pumps, the fuel is delivered through the pressure (delivery) pipes to the injectors.
Return fuel from the unit pumps passes via a channel in the cylinder block to the overflow valve, which is placed in
the outlet from the cylinder head fuel channel.
The overflow valve controls the feed pressure in the fuel system.
The high feed pressure ensures filling of the unit pumps.
The fuel pump has a very high flow and excess fuel helps to cool the unit pumps.
After the overflow valve, the fuel passes via a cooler to the tank.
Figure 1
Fuel control valve (FCV), description
The fuel control valve controls fuel flow to the high-pressure pumps. It delivers the fuel volume needed to reach or maintain the fuel
pressure in the distribution pipe (the rail).
Software
Fuel control valve (PWM2303) is used as input signal for Engine protection, see Engine Protection

Figure 1

1. Solenoid valve
2. Fuel inlet
3. Fuel to high-pressure pumps
4. Return fuel to tank
5. Overflow valve
Injectors, description
Injection timing and the fuel amount to be injected is determined by the control unit E-ECU, which gives signals to the electro-
magnetically controlled fuel valve in the injector's valve housing. The duration of the injection time determines the amount of fuel that
is injected into the cylinder. The 'common rail' system enables more than one injection during the piston's working phase, thus giving
flexible control of the combustion process.
The injection pressure is determined by the pressure in the rail and can vary between 500 bar to 1400 bar (7252–20305 PSI).
The injector nozzles have six holes and are designed to give a uniform spray pattern, despite the angled unit injector and injector
nozzle.

Figure 1

Figure 2
MID 128 SID 42 Fuel control unit
Description and measuring

PWM2303 Proportional solenoid valve, common rail fuel control unit

Function Controls the common rail fuel control unit.
Wiring diagram
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Control unit/ Control cable (+) ≈0Ω
cable harness: 1–A12
Return cable (-)
2–A16

Component: 1–2 ≈4Ω

≈∞Ω
1–

2–
Subsystem: A12–A16 ≈4Ω
Fuel rail pressure, checking
Op nbr 237-037

Total procedure time (hr): 0.70

Testing conditions

1. Batteries are in good conditions and fully charged.

2. There is no fault code displayed on the VCADS Pro.

Pressure checking procedures

1. Place the machine in service position B, see Service positions.

2. Turn off the electric power with the battery disconnect switch.

3. Connect the VCAD Pro computer to the machine through the service socket (1).
Start the VCADS Pro engine test, 23017-3 fuel supply pressure check.

Figure 1
VCADS Pro, connection

1. Service socket

NOTE!
This test is used only if there are the engine starting problems.
Engine starting condition

4. Remove the injector cover (1) from the engine, disconnect all cables (2) for the injectors.
NOTE!
Isolate the disconnected cables.

Figure 2
Injector cables, disconnection

1. Injector cover
2. Injector cables
 5. Crank the engine with the starter motor for 15 to 20 seconds, check if the fuel rail pressure values are according to the
specifications. See Fuel pressure, specifications.
NOTE!
Engine crank speed: 150 ±30 rpm
In case the engine crank speed is not normal
Check the battery, cables, starter motor and engine load.
In case the fuel feed pressure is not normal
Check the fuel filter and the fuel feed pump.
In case the rail pressure is not normal
Check the fuel control unit, the high pressure pump and the rail pressure relief valve.
NOTE!
If there are very abnormal results, check the fuel rail pressure sensor and the E-ECU.

6. Stop the engine.

7. Save the job card, and connect the injector cables.

Engine running, without load condition

8. Start the VCADS Pro engine test, 23017-3 fuel supply pressure check.

9. Start the engine.

10. Put the control lockout lever in the unlocked (up) position.
Check if the fuel rail pressure values are according to the specifications when there is a load below 28%. See Fuel pressure,
specifications.
NOTE!
Check the engine load at I-ECU service mode.
NOTE!
Check the pressure values at the different positions of the engine speed control switch, see Fuel pressure, specifications.
In case the charge air pressure is too low
Check the air intake system.
In case the engine load is too high
Check the hydraulic system load and the engine conditions.
In case the fuel feed pressure is too low
Check the fuel filter and the fuel feed pump.
In case the rail pressure is too low
Check the fuel control unit, the high pressure pump and the rail pressure relief valve.
In case the rail pressure is too high
Check the Injectors.
NOTE!
If there are very abnormal results, check the fuel rail pressure sensor and the E-ECU.

11. Stop the engine.

12. Save the job card.

Engine running, with load condition

13. Start the VCADS Pro engine test, 23017-3 fuel supply pressure check.

14. Start the engine.

15. Check if the fuel rail pressure values are according to the specifications when there is a load above 60%. See Fuel pressure,
specifications.
NOTE!
Check the engine load at I-ECU service mode.
NOTE!
Engine speed: 1900 rpm
NOTE!
Create the hydraulic load by moving the dipper arm and the bucket to their full stroke.
In case the charge air pressure is too low
 Check the air intake system.
In case the engine load is too high
Check the hydraulic system load and the engine conditions.
In case the fuel feed pressure is too low
Check the fuel filter and the fuel feed pump.
In case the rail pressure is too low
Check the fuel control unit, the high pressure pump and the rail pressure relief valve.
In case the rail pressure is too high
Check the hydraulic system load.
NOTE!
If there are very abnormal results, check the fuel rail pressure sensor and the E-ECU.

16. Stop the engine.

17. Save the job card, and disconnect the VCADS Pro cable.

18. Restore the machine to operating condition.

MID128 PSID97 / 128 PSID97
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID PSID97 Pressure Release Valve
Machine display message
Text presentation 128 PSID97

Reference Fuel system, description

Fuel control valve (FCV), description
Injectors, description

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Leakage when the pressure
FMI 0 relief valve is open
Symptom: Possible causes:

Red central warning
Defective rail pressure sensor

Buzzer sounds continuously
Defective fuel control unit

Error message screen
Pressure relief valve locked in open

Max. speed is limited to 1100 rpm by position
the engine protection function

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 PID 164 Injection control pressure

MID 128 SID 42 Fuel control unit
Fuel rail pressure, checking

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Pressure relief valve stuck
FMI 7 closed
Symptom: Possible causes:

Red central warning
Pressure relief valve stuck closed

Buzzer sounds continuously
Defective fuel control unit

Error message screen
Defective rail pressure sensor

Max. speed is limited to 1100 rpm by
the engine protection function

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 PID 164 Injection control pressure

MID 128 SID 42 Fuel control unit
Fuel rail pressure, checking

Fault mode Detection conditions:The engine control unit (E-ECU) registers: High common rail pressure
FMI 11 when the pressure relief valve is open
Symptom: Possible causes:

Red central warning
Defective rail pressure sensor

Buzzer sounds continuously
Pressure relief valve stuck closed

Error message screen
Defective fuel control unit

Max. speed is limited to 1100 rpm by
the engine protection function

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 PID 164 Injection control pressure

MID 128 SID 42 Fuel control unit
Fuel rail pressure, checking

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Pressure relief valve is open
FMI 14 Symptom: Possible causes:

Red central warning
Fuel control valve stuck open

Buzzer sounds continuously
Defective fuel control unit

Error message screen
Defective rail pressure sensor

Max. speed is limited to 1100 rpm by
Pressure relief valve locked in open
the engine protection function position

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 SID 42 Fuel control unit

Fuel rail pressure, checking

Guided Diagnostics
MID128 SID211 / 128 SID211
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID SID211 Sensor Supply Voltage #2 (+5V DC)
Machine display message
Text presentation 128 SID211

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above 5.5
FMI 3 V (EB17)(EB18)
Symptom: Possible causes:

Red central warning
Short circuit to higher voltage

Buzzer sounds one time
Defective sensor

Error message screen

Incorrect values from engine's sensors
generated

Low power

Action 128 PID94

128 PID100
128 PID110
128 PID172

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below 4.5
FMI 4 V (EB17)(EB18)
Symptom: Possible causes:

Red central warning
Short circuit to lower voltage

Buzzer sounds one time
Defective sensor

Error message screen

Incorrect values from engine's sensors
generated

Low power

Action 128 PID94

128 PID100
128 PID110
128 PID172

Guided Diagnostics
MID128 SID22 / 128 SID22
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID SID22 Timing sensor, crank
Machine display message
Text presentation 128 SID22

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: intermittent signal loss or
FMI 2 signal error (EA37/EA38)
Symptom: Possible causes:

Red central warning
Electric interference on speed signal

Buzzer sounds one time
Loose connection

Error message screen
Poor insulation or defective cable

Low power because of engine
Incorrectly installed sensor
protection
Defective sensor

Engine runs rough/ varying engine
Damaged gear teeth on flywheel
speed

Misfiring

Engine stops/cannot be started (on
condition that camshaft signal is also
incorrect)

Engine is difficult to start, only after a
long time of cranking

Action 128 SID22

Sensor and gear teeth inspection

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the signal from the
FMI 3 speed sensor is missing (EA37/EA38)
Symptom: Possible causes:

Red central warning
Loose connection

Buzzer sounds one time
Incorrectly installed sensor

Error message screen
Defective sensor

Low power because of engine
Positive cable short-circuited to
protection voltage

Engine runs rough/ varying engine
Positive cable short-circuited to frame
speed ground

Misfiring
Negative cable short-circuited to

Engine stops/cannot be started (on voltage
condition that camshaft signal is also
Open circuit on positive cable
incorrect)
Open circuit on negative cable

Engine is difficult to start, only after a
Short-circuit between cables or in
long time of cranking component

Action 128 SID22

Fault mode Detection conditions:The engine control unit (E-ECU) registers: abnormal frequency of signal
FMI 8 from the speed sensor (EA37/EA38)
 Symptom: Possible causes:

Red central warning
Electric interference on speed signal

Buzzer sounds one time
Incorrectly installed sensor (incorrect

Error message screen distance to sensor gear)

Low power because of engine
Defective sensor
protection
Damaged gear teeth on flywheel

Engine runs rough/ varying engine
speed

Misfiring

Engine stops/cannot be started (on
condition that camshaft signal is also
incorrect)

Engine is difficult to start, only after a
long time of cranking

Action 128 SID22

Sensor and gear teeth inspection

Guided Diagnostics
Go back to Index Page

128 SID22
Description and measuring

SE2701 Engine speed sensor (crankshaft)

Function Measures engine speed from the flywheel. Measurement is taken
on gear by converter.
Wiring diagram
VCADS Pro See test 28407-3 Sensor values, monitoring
EA31, engine speed (+)
EA30, engine speed (–)
Control unit/ Signal line (+) 1 ≈ 75 ~ 110 KΩ
cable harness: - Frame ground

1) 2) 3) 4)
Component 1-2 ≈ 775–945 Ω

1 - Frame ground ≈∞Ω

2 - Frame ground ≈∞Ω
1) 2) 3) 4)
Go back to Index Page

128 SID231
Description and measuring

SID231 SAE J1939 control link, failure

Function Checks if the communication between ECUs is down.
Wiring diagram
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Subsystem U ≈2.5 ~ 3.0 V
CAN H -

U ≈ 2.0 ~ 2.5 V
CAN L -

CAN H - L U≈0~1V

Voltage levels J1939 CAN-bus

MID128 SID232 / 128 SID232
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID SID232 5 V supply
Machine display message
Text presentation 128 SID232

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above 5.5
FMI 3 V (EA7)(EA11)
Symptom: Possible causes:

Red central warning
Short circuit to higher voltage

Buzzer sounds one time
Defective sensor

Error message screen

Incorrect values from engine's sensors
generated

Low power

Action 128 PID102

128 PID105
MID 128 PID 164 Injection control pressure
128 PID175

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below 4.5
FMI 4 V (EA7)(EA11)
Symptom: Possible causes:

Red central warning
Short circuit to lower voltage

Buzzer sounds one time
Defective sensor

Error message screen

Incorrect values from engine's sensors
generated

Low power

Action 128 PID102

128 PID105
MID 128 PID 164 Injection control pressure
128 PID175

Guided Diagnostics
MID128 SID240 / 128 SID240
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID SID240 Programme memory
Machine display message
Text presentation 128 SID240

Reference

Fault mode diagnosis

Fault mode Detection conditions:

FMI 2 Symptom: Possible causes:

Red central warning
Self-test error in engine control unit

Buzzer sounds continuously

Error message screen

Engine does not start

Action Parameters should be checked if malfunction has occurred in connection with programming
If malfunction has occurred during operation, the E-ECU should be re-programmed or replaced

Guided Diagnostics
MID128 SID240 / 128 SID240
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID SID240 Programme memory
Machine display message
Text presentation 128 SID240

Reference Engine control unit E-ECU, function description

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: Self-test error in engine
FMI 2 control unit
Symptom: Possible causes:

Red central warning
Programming error

Buzzer sounds continuously
Internal error in the engine control unit

Error message screen

Engine does not start

Action Parameters should be checked if malfunction has occurred in connection with programming
If malfunction has occurred during operation, the E-ECU should be re-programmed or replaced

Guided Diagnostics
Go back to Index Page

Engine control unit E-ECU, function description

Control unit's sensors
The D6D engine's injection system is controlled completely by electronics with regards to injected amount and injection timing. The
system is called EMS (Engine Management System).
This section briefly describes the parts that are mounted on the engine. A number of other parts affect the system, for example, the
sensor for engine speed.
The central part in the system, control unit E-ECU, is located on the right side of the air cleaner. All cable connections for the engine
sensors have connectors with DIN-standard.

Figure 1
E-ECU, position
Control unit
The control unit E-ECU is the central part of the injection system. The unit is mounted in brackets with rubber dampers.
The E-ECU receives continuous information from V-ECU (requested engine speed) and a number of sensors on the engine. It also
calculates the fuel amount and at what time the fuel should be injected into the cylinders.
The E-ECU stores information if a malfunction should occur, or if something in the system is abnormal. Even malfunctions that occur
sporadically are stored in the control unit and can thus be traced at a later time.
Functions

Fuel amounts, injection pump

Temperatures

Preheating coil, preheating

Operating speed (rpm)
MID128 SID232 / 128 SID232
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID SID232 5 V supply
Machine display message
Text presentation 128 SID232

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is above 5.5
FMI 3 V (EA7)(EA11)
Symptom: Possible causes:

Red central warning
Short circuit to higher voltage

Buzzer sounds one time
Defective sensor

Error message screen

Incorrect values from engine's sensors
generated

Low power

Action 128 PID102

128 PID105
MID 128 PID 164 Injection control pressure
128 PID175

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below 4.5
FMI 4 V (EA7)(EA11)
Symptom: Possible causes:

Red central warning
Short circuit to lower voltage

Buzzer sounds one time
Defective sensor

Error message screen

Incorrect values from engine's sensors
generated

Low power

Action 128 PID102

128 PID105
MID 128 PID 164 Injection control pressure
128 PID175

Guided Diagnostics
MID128 SID253 / 128 SID253
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID SID253 Calibration memory EEPROM
Machine display message
Text presentation 128 SID253

Reference

Fault mode diagnosis

Fault mode Detection conditions:

FMI 2 Symptom: Possible causes:

Red central warning
Self-test error in engine control unit

Buzzer sounds continuously

Error message screen

Engine does not start

Action Parameters should be checked if malfunction has occurred in connection with programming
If malfunction has occurred during operation, the E-ECU should be re-programmed or replaced

Fault mode Detection conditions:

FMI 12 Symptom: Possible causes:

Red central warning
Self-test error in engine control unit

Buzzer sounds continuously

Error message screen

Engine does not start

Action Parameters should be checked if malfunction has occurred in connection with programming
If malfunction has occurred during operation, the E-ECU should be re-programmed or replaced

Guided Diagnostics
MID128 SID254 / 128 SID254
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID SID254 Controller 1
Machine display message
Text presentation 128 SID254

Reference

Fault mode diagnosis

Fault mode Detection conditions:

FMI 3 Symptom: Possible causes:

Red central warning
Self-test error in engine control unit

Buzzer sounds continuously

Error message screen

Engine does not start

Action Reprogram the control unit

If the fault remains:
Replace the control unit (internal fault in the control unit)

Fault mode Detection conditions:

FMI 8 Symptom: Possible causes:

Red central warning
Self-test error in engine control unit

Buzzer sounds continuously

Error message screen

Engine does not start

Action Reprogram the control unit

If the fault remains:
Replace the control unit (internal fault in the control unit)

Fault mode Detection conditions:

FMI 12 Symptom: Possible causes:

Red central warning
Self-test error in engine control unit

Buzzer sounds continuously

Error message screen

Engine does not start

Action Reprogram the control unit

If the fault remains:
Replace the control unit (internal fault in the control unit)

Guided Diagnostics
MID128 SID42 / 128 SID42
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID SID42 Fuel Control Unit
Machine display message
Text presentation 128 SID42

Reference

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: voltage too high (EA16)
FMI 3 Symptom: Possible causes:

Red central warning
Short-circuit to Ubat, low side

Buzzer sounds continuously
Defective PWM valve

Error message screen

Also sets MID 128 PSID 97 FMI 14

Max. speed is limited to 1100 rpm by
the engine protection function

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 SID 42 Fuel control unit

Fault mode Detection conditions:The engine control unit (E-ECU) registers: voltage too low (EA12)
FMI 4 Symptom: Possible causes:

Red central warning
Short-circuit to frame ground, high side

Buzzer sounds continuously
Defective PWM valve

Error message screen

Also sets MID 128 PSID 97 FMI 14

Max. speed is limited to 1100 rpm by
the engine protection function

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 SID 42 Fuel control unit

Fault mode Detection conditions:The engine control unit (E-ECU) registers: current too low (EA12/EA16)
FMI 5 Symptom: Possible causes:

Red central warning
Short-circuit to Ubat, high side

Buzzer sounds continuously
Open circuit

Error message screen
Defective PWM valve

Also sets MID 128 PSID 97 FMI 14

Max. speed is limited to 1100 rpm by
the engine protection function

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 SID 42 Fuel control unit

Fault mode Detection conditions:The engine control unit (E-ECU) registers: current too high (EA12/
FMI 6 EA16)
Symptom: Possible causes:

Red central warning
Short circuit in PWM valve

Buzzer sounds continuously
Defective PWM valve

Error message screen

Also sets MID 128 PSID 97 FMI 14

Max. speed is limited to 1100 rpm by
the engine protection function

Low power because of engine
protection

Rail pressure limitation

Engine shutdown

Action MID 128 SID 42 Fuel control unit

Guided Diagnostics
MID128 SID70 / 128 SID70
SAE code
MID/Control Unit MID128 Engine ECU
PID/PPID/SID/PSID SID70 Air inlet heater driver #1
Machine display message
Text presentation 128 SID70

Reference Preheating, description

Fault mode diagnosis

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is equal to
FMI 3 Ubat(EB7)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to Ubat

Buzzer sounds continuously
Relay continuously activated

Error message screen

Relay may be continuously activated

High cooling fan speed for charge-air
cooling due to high inlet temperature

Poor battery

Action 128 SID70

Fault mode Detection conditions:The engine control unit (E-ECU) registers: that the voltage is below
FMI 4 0.91xUbat (EB7)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to frame

Buzzer sounds one time ground

Error message screen
Contact resistance in connectors

Preheating not functioning
Defective relay

White smoke during cold starts

Difficult to start in extreme cold

Action 128 SID70

Fault mode Detection conditions:The engine control unit (E-ECU) registers: open circuit (EB7)
FMI 5 Symptom: Possible causes:

Red central warning
Defective fuse on feed cable

Buzzer sounds one time
Open circuit in preheating coil

Error message screen
Open circuit in cable harness

Preheating not functioning
Defective relay

Difficult to start in extreme cold

Action 128 SID70

Guided Diagnostics
Go back to Index Page

128 SID70
Description and measuring

HE2501 Induction air preheating coil

Function Warms induction air in engine induction manifold.
Wiring diagram

EB5, diagnostic signal

EB31, activation preheating relay signal
Component: Preheating coil - Frame ≈ 0 Ω
ground

1) 2) 3) 4)
Specific part of 87A - ground ≈ 21 V (active)
system: ≈ 0 V (inactive)
1) Measuring on heating coil 2) 3)

Preheating time (recommended)

Engine coolant temperature, ºC (ºF) Time for preheating, seconds

> 20 0
12 25
10 25
0 25
< - 10 50
MID140 PSID200 / 140 PSID200
SAE code
MID/Control Unit MID140 Information display
PID/PPID/SID/PSID PSID200 Data Link, MID128
Machine display message
Text presentation 140 PSID200

Reference

Fault mode diagnosis

Fault mode Detection conditions:The instrument control unit (I-ECU) registers: that bus communication is
FMI 9 missing with E-ECU on CAN/J1939
Symptom: Possible causes:

Red central warning
Open circuit on bus communication

Buzzer sounds one time (cable harness)

Error message screen
Short-circuit to voltage on control link
(SAE J1939)

Short-circuit to frame ground on
control link (SAE J1939)

Leads in control link (SAE J1939)
short-circuited to each other

Action 140 SID231

Fault mode Detection conditions:The instrument control unit (I-ECU) registers: that bus communication is
FMI 12 missing with E-ECU on J1708/J1587
Symptom: Possible causes:

Red central warning
Open circuit on bus communication

Buzzer sounds one time (cable harness)

Error message screen
Short-circuit to voltage on information
link

Short-circuit to frame ground on
information link

Leads in information link short-
circuited to each other

Action 140 SID250

Guided Diagnostics
MID140 PSID216 / 140 PSID216
SAE code
MID/Control Unit MID140 Information display
PID/PPID/SID/PSID PSID216 Data Link, MID187
Machine display message
Text presentation 140 PSID216

Reference

Fault mode diagnosis

Fault mode Detection conditions:The instrument control unit (I-ECU) registers: that bus communication is
FMI 9 missing with V-ECU on CAN/J1939
Symptom: Possible causes:

Red central warning
Open circuit on bus communication

Buzzer sounds one time (cable harness)

Error message screen
Short-circuit to voltage on control link
(SAE J1939)

Short-circuit to frame ground on
control link (SAE J1939)

Leads in control link (SAE J1939)
short-circuited to each other

Action 140 SID231

Fault mode Detection conditions:The instrument control unit (I-ECU) registers: that bus communication is
FMI 12 missing with V-ECU on J1708/J1587
Symptom: Possible causes:

Red central warning
Open circuit on bus communication

Buzzer sounds one time (cable harness)

Error message screen
Short-circuit to voltage on information
link

Short-circuit to frame ground on
information link

Leads in information link short-
circuited to each other

Action 140 SID250

Guided Diagnostics
MID187 SID254 / 187 no signal
SAE code
MID/Control Unit MID187 Vehicle Control Unit
PID/PPID/SID/PSID SID254 Controller 1
Machine display message
Text presentation 187 no signal

Reference

Fault mode diagnosis

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: Operating System halt
Symptom: Possible causes:

Red central warning
Self-test error in vehicle control unit

Buzzer sounds continuously (V-ECU)

Error message screen

Action Reprogram the control unit

If the fault remains:
Replace the V-ECU (Internal fault in the V-ECU).

Guided Diagnostics
PID96 MID187 / 187 PID96
SAE code
MID/Control Unit MID187 Vehicle Control Unit
PID/PPID/SID/PSID PID96 Fuel level sensor
Machine display message
Text presentation 187 PID96

Reference

Fault mode diagnosis

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that the fuel level is below
FMI 0 the warning level for 30 seconds
Symptom: Possible causes:

Red central warning
low fuel level

Buzzer sounds one time
Defective sensor

Error message screen

Action Check fuel level

Check sensor condition

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that the voltage is below 0.5
FMI 4 V for 3 seconds (VA15)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to frame

Buzzer sounds one time ground

Error message screen
Defective sensor

Action 187 PID96

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that the voltage is above 4.5
FMI 5 V for 3 seconds (VA15)
Symptom: Possible causes:

Red central warning
Signal line short-circuited to higher

Buzzer sounds one time voltage

Error message screen
Open circuit on signal line

Open circuit on ground line

Loose connection

Action 187 PID96

Guided Diagnostics
187 PID96
Description and measuring

SE2303 Sensor, fuel level

Function Measures the fuel level.
Wiring
diagram
Installing/ Tightening torque:
Adjusting: VCADS Pro:
2–A15 ≈0Ω
3–A63

Component: 2– ≈∞Ω
3–
2–3 ≈ 82 ~ 357.8 Ω
Subsystem: A15–A63 ≈ 1.7 (full) ~ 3.4
(empty)
MID187 PPID1190 / 187 PPID1190
SAE code
MID/Control Unit MID187 Vehicle Control Unit
PID/PPID/SID/PSID PPID1190 Power shift PPV current
Machine display message
Text presentation 187 PPID1190

Reference

Fault mode diagnosis

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that the feedback voltage is
FMI 3 above 4.4 V(VA5)
Symptom: Possible causes:

Red central warning
Short-circuit to Ubat, high side

Buzzer sounds one time

Error message screen

Engine overloaded

Action 187 PPID1190

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that the feedback voltage is
FMI 4 below 0.12 V(VA5)
FMI 5 Symptom: Possible causes:

Red central warning
Short-circuit to frame ground, high side

Buzzer sounds one time
Short-circuit to Ubat, low side

Error message screen
Open circuit

Engine overloaded

Action 187 PPID1190

Guided Diagnostics
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187 PPID1190

Description and measuring

MA9102 Proportional solenoid valve for pump flow control

Function Controls the pump flow.
Wiring diagram
Installing/ Tightening torque:
Adjusting: VCADS Pro:

Control unit/ Control cable (+) ≈0Ω

cable harness: 1–A32
Return cable (-)
2–A5

Component: 1–2 ≈ 17.5 Ω (20 °C)

≈∞Ω
1–

2–
Subsystem: A5–A32 ≈ 17.5 Ω (20 °C)
MID187 PPID1191 / 187 PPID1191
SAE code
MID/Control Unit MID187 Vehicle Control Unit
PID/PPID/SID/PSID PPID1191 Flow control PPV current
Machine display message
Text presentation 187 PPID1191

Reference

Fault mode diagnosis

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that the feedback voltage is
FMI 3 above 4.4 V(VA30)
Symptom: Possible causes:

Red central warning
Short-circuit to Ubat, high side

Buzzer sounds one time

Error message screen

Action 187 PPID1191

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that the feedback voltage is
FMI 4 below 0.12 V(VA30)
FMI 5 Symptom: Possible causes:

Red central warning
Short-circuit to frame ground, high side

Buzzer sounds one time
Short-circuit to Ubat, low side

Error message screen
Open circuit

Action 187 PPID1191

Guided Diagnostics
187 PPID1191

Description and measuring

PWM9109 Proportional solenoid valve for X1 flow control

Function Controls the X1 flow.
Wiring diagram
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Control unit/ Control cable (+) ≈0Ω
cable harness: 1–A56
Return cable (-)
2–A30

Component: 1–2 ≈ 11.5 Ω (20 °C)

≈∞Ω
1–

2–
Subsystem: A56–A30 ≈ 11.5 Ω (20 °C)
MID187 PSID200 / 187 PSID200
SAE code
MID/Control Unit MID187 Vehicle Control Unit
PID/PPID/SID/PSID PSID200 Data Link, MID128
Machine display message
Text presentation 187 PSID200

Reference

Fault mode diagnosis

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that bus communication is
FMI 9 missing with E-ECU on CAN/J1939
Symptom: Possible causes:

Red central warning
Open circuit on bus communication

Buzzer sounds one time (cable harness)

Error message screen
Short-circuit to voltage on control link
(SAE J1939)

Short-circuit to frame ground on
control link (SAE J1939)

Leads in control link (SAE J1939)
short-circuited to each other

Action 187 SID231

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that bus communication is
FMI 12 missing with E-ECU on J1708/J1587
Symptom: Possible causes:

Red central warning
Open circuit on bus communication

Buzzer sounds one time (cable harness)

Error message screen
Short-circuit to voltage on information
link

Short-circuit to frame ground on
information link

Leads in information link short-
circuited to each other

Action 187 SID250

Guided Diagnostics
MID187 PSID202 / 187 PSID202
SAE code
MID/Control Unit MID187 Vehicle Control Unit
PID/PPID/SID/PSID PSID202 Data Link, MID140
Machine display message
Text presentation 187 PSID202

Reference

Fault mode diagnosis

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that bus communication is
FMI 9 missing with I-ECU on CAN/J1939
Symptom: Possible causes:

Red central warning
Open circuit on bus communication

Buzzer sounds one time (cable harness)

Error message screen
Short-circuit to voltage on control link
(SAE J1939)

Short-circuit to frame ground on
control link (SAE J1939)

Leads in control link (SAE J1939)
short-circuited to each other

Action 187 SID231

Fault mode Detection conditions:The vehicle control unit (V-ECU) registers: that bus communication is
FMI 12 missing with I-ECU on J1708/J1587
Symptom: Possible causes:

Red central warning
Open circuit on bus communication

Buzzer sounds one time (cable harness)

Error message screen
Short-circuit to voltage on information
link

Short-circuit to frame ground on
information link

Leads in information link short-
circuited to each other

Action 187 SID250

Guided Diagnostics