VOLVO 7748542_US_ Installation EMS 2 - D13

Installation EMS 2 Industrial Engines

I 1(1)

TAD1341GE, TAD1342GE, TAD1343GE, TAD1344GE TAD1345GE, TAD1350GE, TAD1351GE, TAD1352GE TAD1353GE TAD1340VE, TAD1341VE, TAD1342VE, TAD1343VE TAD1344VE TAD1345VE

Content Safety Information ...................................................................................... 2 Installation Tools and Documentation ...................................................... 4 Special Tools ............................................................................................ 4 System Information .................................................................................... 5 EMS ........................................................................................................... 5 Control System Installation ..................................................................... 17 Connection ............................................................................................. 17 Parameter Setting .................................................................................. 34 Diagnostic Function ............................................................................... 40 Fault Code Register ............................................................................... 43 Alphabetical index .................................................................................... 57

1

Safety Information Presentation

Working methods

This installation manual contains information for installing and carrying out function and performance checks on the EMS 2 system (electronic control of the injection system). This instruction manual is intended only for professional use. Read the instructions carefully before starting the installation. If the installation is performed in an incorrect manner, it may cause personal injury or damage to property and machinery. Ask your Volvo Penta dealer for help if there is anything in this manual that you do not understand or are uncertain about.

The work must be performed by a Volvo Penta workshop or other authorized, well-equipped workshop by qualified and experienced personnel. These instructions refer to such personnel as fitters. This installation manual is intended to be used together with the operator's manual for the engine concerned. The fitter is responsible for ensuring that the system functions in accordance with these installation instructions. Volvo Penta disclaims all responsibility for injury to persons or damage to property that may occur as a result of not following the installation guidelines, or for work carried out by unqualified personnel.

! This symbol is used in the 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 installation 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! Indicates a situation which, if not avoided, could result in property damage. NOTICE! Used to draw attention to important information that will facilitate work or operations. This symbol is used on our products in certain cases and it refers to important information in the operator's manual. Make sure that warning and information symbols on the engine are clearly visible and legible. Replace symbols that have been damaged or painted over.

2

7748542 10-2009

Safety Information Set out below is a summary of the risks and safety measures that must be observed or carried out when the EVC system is installed and calibrated.

! Disconnect connectors to the EMS control unit before any arc welding is carried out. Turn the current off at the main switches. Undo and remove the control unit connectors. Reconnect the EMS 2 control unit connectors once welding is completed and the welding equipment has been removed.

! Take care to keep clear of the engine's moving parts during functional checks and operations. There is a risk for personal injury when approaching a running engine. Remember that loose clothing and long hair can fasten in rotating parts and cause serious injury.

! Never work on an engine that is suspended from lifting gear (a crane or similar).

! The engine must not be run in areas where there are explosive materials or gases.

! Only start the engine in well-ventilated places. If the engine is operated in an enclosed space, make sure that there is sufficient ventilation to remove the exhaust gases and crankcase fumes from the workplace.

7748542 10-2009

! Never expose battery compartments to open flames or electrical sparks. Never smoke in the vicinity of the batteries. Batteries generate hydrogen gas during charging, which can combine with air to form an explosive mixture. This gas is highly flammable and explosive. Incorrect connection of the batteries may cause sparks that in turn cause an explosion resulting in damage. Do not switch battery connections when attempting to start the engine (risk for sparks) and do not lean over the batteries. Refer to the instructions in the engine operator's manual.

! Make sure that the positive (+) and negative (-) battery cables are correctly connected to the corresponding battery terminals. Serious damage may be caused to the electrical equipment if the cables are transposed. Refer to the wiring diagram in the engine operator's manual.

! Always wear eye protection when charging or handling the batteries. Battery electrolyte contains sulfuric acid which is highly corrosive. If electrolyte comes into contact with bare skin, wash the exposed area immediately with copious amounts of clean water and soap. Then seek medical attention. If you get battery electrolyte in your eyes, flush them immediately (preferably using eye wash equipment) with copious amounts of clean water. Then seek immediate medical attention.

3

Installation Tools and Documentation, Special Tools

Installation Tools and Documentation Special Tools

p0005125

3838619 VODIA, diagnostic tool VODIA, complete with cable harness Refer to the VODIA operators manual when ordering separate parts.

9812519 Multimeter Multimeter

Other Special Equipment Other special equipment The tools below are used for work on the engine wire harness. The tools are not part of the Volvo Penta range, and must be ordered from AMP or Deutsch dealers. Contact Volvo Penta Quality Action Center if you have trouble finding a dealer. AMP connector: 42-pin CIU, 62-pin EMS, 2 and 3 pin Bosch etc.

P0003813

HDT-48–00 Press tool

P0003810

AMP 726 519 Removal tool, 2.8 mm pin width

P0003811

AMP 825 514 Press tool For 4.8 and 6.3 cable shoes. Flat-pin connectors.

4


P0003809

AMP 726 519 Removal tool, 0,06 inch pin width

P0003811 P0003813


AMP 238 635 Press tool

P0003814

GHW 50000 017 586 Removal tool, 2.8 mm pin width For GHW connector (relay box)

7748542 10-2009

System Information, EMS

System Information EMS Motorstyrsystem EMS 2 stands for “Engine Management System” and is an electronic system with CAN communications (Controller Area Network) for control of diesel engines. The system has been developed by Volvo Penta and includes fuel control and diagnosis function. The system consists of a control module, six unit injectors, a number of sensors that supply the control module with measurements, sockets for diagnosis and functional checks. The engine can be connected to a communication interface comprising a CAN-link and a serial link.

CAN (Controller Area Network) The CAN J1939 link handles all communication between the engine control module EMS 2 and the CIU, in addition to the diagnostics that are handled by the so called J1708/J1587 link. The CAN link is much faster than the J1708/J1587 link. The CAN link has been prepared to connect to other components with SAE J1939 protocol such as instrument panels and transmissions. If, for some reason, a fault develops on the CAN link, signals for the rpm-potentiometer and the start and stop knobs are taken over by the J1708/J1587 link. However, instrument and indicator lamps are completely turned off. If a fault occurs on both links, GE engines maintain engine speed, while VE engines go to idle. The only way to shut off the engine in this case is to use the auxiliary stop (AUX-STOP) placed on the engine’s left side.

7748542 10-2009

5


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, indicator lamps, contacts and potentiometers are controlled by this bus. The slower J1708/J1587 link handles diagnostic information for, among other things, the flashing code. The diagnosis tool VODIA also uses the J1708/J1587 link to communicate with the system. P0002060

6

7748542 10-2009


Fuel control The engine’s fuel requirement is analyzed up to 100 times per second (depending on engine rpm). The engine’s injection amount and injection timing is controlled electronically via fuel valves on the unit injectors. This means that the engine always receives the correct volume of fuel in all operating conditions, which offers lower fuel consumption, minimal exhaust emissions etc. The control module checks and controls the unit injectors so that the correct amount of fuel is injected into each cylinder. It calculates and sets the injection angle. The control is primarily performed using the speed sensors and the combined sensor for boost pressure/charge air temperature. The control module affects the unit injectors via an electronic signal to the unit injectors’ electromagnetic fuel valve, which can open and close. When the fuel valve is open, fuel flows through the unit injector hole and out through the fuel channel. Fuel is not sprayed into the cylinder in this position. When the fuel valve closes, pressure starts to build from the unit injector’s mechanically operated pump plunger. When sufficient pressure has developed, fuel is injected into the cylinder via the unit injector’s injector section. The fuel valve is re-opened and pressure in the unit injector decreases at the same time as the fuel injection to the cylinder stops. In order to determine when the fuel valve shall open or close, the control module has access to signals from sensors and switch contacts.

Altitude correction The control unit is fitted with an atmospheric air pressure sensor and an altitude correction function for engines operating at high altitudes. This function limits the fuel volume in relation to ambient air pressure. This is to prevent smoke, high exhaust temperature and to protect the turbocharger from over-speeding. Diagnosis function The task of the diagnosis function is to detect and locate disturbances within the EMS 2 system, to protect the engine, and to provide information about problems that have developed. If a malfunction is discovered, this is announced by warning lamps, a flashing diagnostic lamp or in plain language on the instrument panel, depending on the equipment used. If a fault code is obtained as a flashing code or in plain language, this is used for guidance in any troubleshooting. Fault codes can also be read by Volvo’s VODIA tool at authorized Volvo Penta workshops. In case of serious malfunctions, the engine is shut down completely, or the control unit reduces the power output (depending on application). A fault code is set as a guide when fault tracing.

Calculating fuel quantity The amount of fuel that is sprayed into a cylinder is calculated by the control module. The calculation determines the time that the fuel valve is closed (when the fuel valve is closed fuel is sprayed into the cylinder). The parameters controlling injected amount of fuel are: •

Requested engine speed

•

Motor protector

•

Temperature

•

Boost air pressure

7748542 10-2009

7


In- and out signals Information from the sensors provides accurate information regarding operational conditions and makes it possible for the control unit processor to calculate the correct injection amount, injection timing and engine condition, among many other things.

Input signals The control unit receives input signals regarding engine operational conditions along with information from the following components: - Coolant temperature sensor - Charge air pressure/charge air temperature sensors - Crankcase pressure sensor - Position sensor - Camshaft - Engine speed sensor - Flywheel - Piston cooling pressure sensor - Coolant level sensor - Oil pressure sensor - Oil level and oil temperature sensors - Fuel pressure sensor - Water-in-fuel sensor - Air filter pressure sensor - Air temperature sensor - Fan speed

Output signals The control unit uses the input signals to control the following components: - Unit injector - Start motor - Alternator - Main relay - Preheat relay - Internal EGR (TAD1350-1353GE only) - Waste gate - Electronic fan control

8

7748542 10-2009


Instruments 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, rpm regulation, preheating, etc. Monitoring - Shows engine speed, charge pressure, charge temperature, coolant temperature, oil pressure, oil temperature, engine hours, battery voltage, instantaneous fuel consumption and fuel consumption (trip fuel). Diagnostic - Shows fault codes in text. Lists previous faults. Parameter setting - Idle speed, alarm limits for oil temperature/coolant temperature, regulation mode (speed droop/isochronous).

DU (Display Unit) DU is an instrument for showing the engines operating values. The values are shown graphically on an LCD display. The display communicates via the CAN link and consists of a computerized unit for attachment to the control panel. It is connected to the CAN link between the engine control unit and CIU or DCU.

P0002061

7748542 10-2009

9


Location of Sensors 2

1

3

8 4

7 5 6

9 14

10 13

12

11

P0004318

1. Extra stop

8. Fan, rpm sensor

2. Combined charge air pressure and charge air temperature sensor

9. Under-pressure sensor, air filter

3. Oil pressure sensor 4. Crankcase pressure sensor 5. Water-in fuel sensor 6. Combined oil level and oil temperature sensor

10. Coolant level sensor, in the expansion tank 11. Coolant temperature sensor 12. Piston cooling pressure 13. Flywheel position and engine speed 14. Camshaft position

7. Fuel pressure sensor

10

7748542 10-2009

3

GN/R

SB

4

18

17

SB

R 2P 1

25

1

P2

12

8

30

SB 4 R1

SB 2

28 27 23 14

2

1P

2

15

1

21

Y

8

Y

10

SB

SB

SB

12 3 4 5 6 7

CAN 2

GR/OR

SB

R 1,0

1 3 P2

4

26

R 3 SB 1

2

BN/OR GR/GN

32

n

BC AE D F

P4

9

21 n

14

21 n

13

Y 1,0 Y 1,0

SB 1,0

GN

BL/GB Y 1,0

1

2

31

2

2

6

1 2

16

Y 1,0 Y 1,0

1 R/BL 1,5

1 Y 1,0

2 1 Y 1,0 CYL. 6 4 3 Y 1,0

2 1 Y 1,0 CYL. 5 4 3 Y 1,0

2 1 Y 1,0 CYL. 4 4 3 Y 1,0

2 1 Y 1,0 CYL. 3 4 3 Y 1,0

2 1 Y 1,0 CYL. 2 4 3 Y 1,0

CYL. 1 4 3 Y 1,0

2

8

60 61

59 62

3

4 5 6

R/BL 1,0

HL

b a 33 34 27 58 57

52 56 30 38 29 25 37 57 60 7 58 59 61 51 55 h l h h l

CONNECTOR A 31 11 7 47 22 15 29 35 39 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24 - + -

49 3 4 31 11 16 CONNECTOR B

1 2

SB

22

GN/SB GN/W BL/GN BL/OR

R 2P 1

OR

4

BN 1,0

4

R 1,0

SB

23

Y 1,0

SB 1,0

GN BL OR/SB GB/SB

R

Y 1,0

Y 1,0

24

Y 1,0 Y 1,0

Y/SB OR 1,0 R/W Y 1,0

SB

GR/SB VO/SB

BL/W

1

4

MAIN RELAY HOLD

W/SB W

GR/R BN/OR LBN GR/R Y 1,0 Y 1,0

SB 1,5 SB 1,5

29

BL

SB 1,0 Y 1,0 Y 1,0

R/BL Y 1,0 R/BL 1,5 R/BL 1,5 R/BL 1,5

CAN J1939 SB 1,5

G

1 2345 B+ B-

20

18

R 25

SB 25

7 8

AB 1 2 3 4 5 6

10

R 25

3

SB 25

17

4 231 4 231

SB 1,0

R W/SB SB BN 1,0 R/BL 1,0

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

Y Y 1,0 Y 1,0

BN 1,0 SB 1,5 Y/SB

SB 2,5 -. BATT R 2,5 . + BATT SWITCHED . + BATT R/BL 1,5 BL STOP J1587 W 1708 W/SB R/BL 1,5

W SB 2,5

OR 1,0

31

SB 2,5

R 2,5

M

1

R/W Y/SB R 2,5

11

30

2

19

1 2

27

28

85 Y/SB 1 R/BL 1,5 2 30 R 1,5 4 R 3 5

R/BL 1,0

12 1 2

5 86 87


Wiring Diagram

P0010912

7748542 10-2009

System Information, EMS 1 Battery (24 V) 2 Main Switch 3 Start motor 4 Alternator 5 Power relay failure 6 Auxiliary stop 7 Connectors, engine 8 Sensor, coolant temperature 9 Sensors, charge air pressure/charge air temperature 10 VODIA socket (diagnostics socket)

Cable colors BL = Blue LBL = Light blue BN = Brown LBN = Light brown GN = Green GR = Gray OR = Orange P = Pink R = Red SB = Black Vo = Violet W = White Y = Yellow Wire cross-sectional area = 0.75 mm² unless otherwise stated.

11 Connector (not used) 12 Sensor, crankcase pressure 13 Sensor, camshaft 14 Sensor, flywheel 15 Sensor, piston cooling pressure 16 Unit injectors(cyl. 1-6) 17 Preheat relay 18 Circuit breaker 19 Main circuit breaker 10 A 20 Preheater 21 Sensor, coolant level 22 Sensor, oil pressure/temperature 23 Sensor, water in fuel 24 Sensor, oil pressure 25 Sensor, fuel pressure 26 Air filter indicator 27 Stop button 28 Jumper 29 Internal EGR (TAD1350–1353GE only) 30 Control unit, EMS 2.2 31 Wastegate Valve 32 Electric fan

7748542 10-2009

13


CIU (Control Interface Unit) CIU (Control Interface Unit)

14

7748542 10-2009


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Key switch, operating current (15+) RPM-potentiometer Tachometer (code 14) Oil pressure, instrument Oil temperature, instrument Coolant temperature, instrument Instrument illumination Idle contact, two position 1500/1800 contact, two position Start switch, spring return Stop switch, spring return Diagnosis contact, spring return Alarm, low oil pressure Alarm, high oil temperature Alarm, high coolant temperature

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Alarm, low coolant level Fuel alarm Diagnostic lamp Overspeed indication (GE) Operation indicator Preheating indication Preheating contact 8-pin Deutsch connecting plug, engine interface Governor contact Battery voltage alarm Termination resistance 120 Ohm 8-pin Deutsch connecting socket Contact, engine protector disconnect Easy Link connector block Control Interface Unit (CIU)

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 other-wise stated.

7748542 10-2009

15


DCU (Display Control Unit) 12345678 8 Y/W

2

GR/Y

3

SB 2,5

4

R 2,5

5

R/BL 2,5

6

BL 2,5

7

W

8

W/SB

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

1

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

11

3 1

D C 2 U 3

1

VO

1

4

2

R/Y

12345678 9 1 2 3 4 5 6 7 8 10

SB/Y

4

R/BL

5

Y

6

SB

7

GN/R

8

GN/Y

9

GN/SB

10

SB/VO

11

SB/GR

12

SB/W

1 3 2

5

6 7

P0004305

1 Stoppkontakt

Kabelfärger

2 Startkontakt

BL = Blue LBL = Lightblue BN = Brown LBN = Lightbrown GN = Green GR = Grey OR = Orange P = Pink R = Red SB = Black VO = Violet W = White Cable area = 0.75 mm2 unless otherwise specified.

3 1-poligt kontaktdonsblock 4 Signalhorn, larmsummer 5 Kontaktblock Easy Link 6 Varvtalspotentiometer 7 Gångindikering 8 Deutsch 8-poligt kontaktdon, engine interface 9 Deutsch 8-poligt kontaktdonshylsa, engine interface 10 Termineringsmotstånd 120 Ω 11 DCU (Display Control Unit)

16

7748542 10-2009

Control System Installation, Connection

Control System Installation Connection General • The installation must be prepared for well and carried out with the greatest care.

• Secure the connecting cable between the engine

and instrument panel with clamps. Bear in mind that connector blocks must be mechanically secured so that they are not exposed to any pulling forces.

• The cables must not be run close by hot engine

components or close to any other heat source. Ensure that the cables are protected from mechanical wear, sharp edges and water splashes. If necessary, the cables can be run through conduits.

• As far as possible, avoid splices in the system wir-

ing. The cables and any splices must be accessible for inspection and service.

NOTICE! Connectors must be assembled “dry”, they must not be filled with petroleum jelly or similar.

7748542 10-2009

17


Power supply NOTICE! The engines are equipped with a 2-pole electrical system. This means that the positive and negative cables from the battery must be connected to the starter motor terminals. The positive cable from the battery may be run via a main switch to terminal 30 on the starter motor. The negative cable from the battery must be connected directly to terminal 31 on the starter motor. Refer to the illustration below.

30

31

P0004300

18

7748542 10-2009


Battery specification Max. battery 2x220 Ah (series connected), 1150 A CCA EN.

Battery charging Standard for all engines is that batteries are supplied with power from the alternator.

Battery cable cross-sectional area The total length (L) of the positive and negative cables determines the cable cross sectional area (A). Max L

(m) (ft)

8 26.2

10 32.8

13 42.6

Min A

(mm2) (in2)

70 0.11

95 0.15

120 0.19

WARNING! Due to fire risk, the cable area should never be less than 70 mm2 (0.1 inch2).

7748542 10-2009

19


CIU TAD1341GE, TAD1342GE, TAD1343GE, TAD1344GE, TAD1345GE, TAD1350GE, TAD1351GE, TAD1352GE, TAD1353GE

B

C

D

A

E

F P0004306

A 8-pin Deutsch connector, from wire harness to engine B Connectors, analog instruments C 3-pin Deutsch connector, Easy Link instrument

20

D For the connection cable, refer to the Instruments page 30 section. E 8-pin Deutsch connector F Extension cables, available in the following lengths: 3, 5, 7, 9, and 11 m

7748542 10-2009


Engine control Refer to System Information page 12 CIU NO = normally open NC = normally closed Start lock (system voltage OFF / ON) Engine system voltage start current (control unit) is 10 A. Ensure that other components in the installation are dimensioned for this current load. Start switch Switch type: closing (NO), spring loaded. Stop switch Switch type: closing (NO), spring loaded. The stop switch is energized during operations via a parameter setting. In this case use a normally closed (NC) switch. RPM potentiometer Nominal revolutions minus 90 rpm: 0.3–1.9 V (preset value 1.17 V) Nominal revolutions plus 90 rpm: 1.9–4.7 V (preset value 4.5 V)

A

A B C P0005827

1.17 V

2.84 V

4.5 V

P0005828

7748542 10-2009

21

Control System Installation, Connection 1800 rpm switch Two-position contact. Idle switch Two-position contact. Closed contact provides idle rpm (900 rpm). Droop value switch Two-position contact. The switch must be closed to provide rpm droop value. Primary control switch Two-position contact. Contact, pre-heating Two-position contact.

22

7748542 10-2009


CIU TAD1340VE, TAD1341VE, TAD1342VE, TAD1343VE, TAD1344VE, TAD1345VE

A 8-pin Deutsch connector, from wire harness to engine B Connectors, analog instruments C 3-pin Deutsch connector, Easy Link instrument

7748542 10-2009

D For the connection cable, refer to the Instruments page 30 section. E 8-pin Deutsch connector F Extension cables, available in the following lengths: 3, 5, 7, 9, and 11 m

23


Engine control Refer to System Information page 12 CIU NO = normally open NC = normally closed

A

Start lock The start lock switch is used to connect the system power, pre-heating and start and stop functions.

B

Engine system voltage start current (control unit) is 10 A. Ensure that other components in the installation are dimensioned for this current load.

C

D

P0003965

A

Stop contact

B

ON contact

C

Start lock

D

Pre-heating contact

Start lock positions

I

Position 0: engine switched OFF Position I: system voltage ON Position II: pre-heating ON (spring return) Position III: start motor ON (spring return) Position S: stop function ON (spring return)

P0003966

A

Pre-heating

B

Start

C

Batt +

D

15 start lock

E

Stop

24

A B C D E

7748542 10-2009

Control System Installation, Connection Control switch Two-position contact. Accelerator pedal Idle: 0.3 1.9 V (preset value 1.17 V) Full throttle: 1.9 4.7 V (preset value 4.5 V) If an accelerator pedal with different resistance and voltage values is used, the control unit must be re-calibrated using the parameter tool; refer to Connection of special tool VODIA page 34.

A B

Idle switch The accelerator pedal has an integral idle switch that acts as an emergency device if the accelerator pedal potentiometer becomes defective. When the accelerator pedal is depressed, a contact is closed and the engine increases in steps to 80 percent of maximum rpm. When the accelerator pedal is released, the contact is opened and the engine slows to idle immediately.

P0004058

7748542 10-2009

25


DCU

B

C A

P0005826

A

8-pin connector from the engine wire harness.

B

3-pin Deutsch connector, Easy Link instrument

C

Connectors, analog instruments (options)

26

7748542 10-2009

Control System Installation, Connection DCU (Display Control Unit) The DCU is connected via the 8-pin databus connector block. Display (optional) Switch type: closing (NO), spring loaded. Stop switch (optional) Switch type: closing (NO), spring loaded. Warning and control lamps (options) Running indication: Max. power 3 W Voltage 24 V

7748542 10-2009

27


Rpm-potentiometer TAD1341GE, TAD1342GE, TAD1343GE, TAD1344GE, TAD1345GE, TAD1350GE, TAD1351GE, TAD1352GE, TAD1353GE The values from the rpm potentiometer in-I or output signal from the connection to an external load distribution system can be set in the DCU. Nominal revolutions minus 120 rpm: 0–10 V (preset value 1 V) Nominal revolutions plus 120 rpm: 0–10 V (preset value 9 V) It is possible to invert the signal; see diagram.

A

A

B

B

C P0005824

C 1V

5V

9V P0005825

1V

5V

A

Nominal revolutions + 120 rpm

A

Nominal revolutions + 120 rpm

B

Nominal revolutions (1500/1800 rpm)

B


C

Nominal revolutions - 120 rpm

C

Nominal revolutions - 120 rpm

9V

Rpm-potentiometer TAD1340VE, TAD1341VE, TAD1342VE, TAD1343VE, TAD1344VE, TAD1345VE It is possible to invert the signal; see the diagram below.

P0005815

P0005816

Max. potentiometer value: 0–10 V (preset value 9V) Min. potentiometer value: 0–10 V (preset value 1V)

28

7748542 10-2009


Warning and Indication Lamps TAD1341GE, TAD1342GE, TAD1343GE, TAD1344GE, TAD1345GE, TAD1350GE, TAD1351GE, TAD1352GE, TAD1353GE The warning and control lamps below are available. Specification for all lamps: Max. power 3 W Voltage 24 V Refer to the CIU System Information page 12.

• Alarm, low oil pressure • Alarm, high oil temperature • Alarm, high coolant temperature • Alarm, low coolant level • Alarm, low fuel level • Alarm, low battery voltage • Diagnostic lamp • Pre-heat indicator

Warning and Indication Lamps TAD1340VE, TAD1341VE, TAD1342VE, TAD1343VE, TAD1344VE, TAD1345VE The warning and control lamps below are available. Specification for all lamps: Max. power 3 W Voltage 24 V Refer to the CIU System Information page 12.

• Alarm, low oil pressure • Alarm, high oil temperature • Alarm, high coolant temperature • Alarm, low coolant level • Alarm, low fuel level • Alarm, low battery voltage • Diagnostic lamp • Pre-heat indicator

7748542 10-2009

29


Instruments Easy Link Instrument (option) Refer to the System Information page 12 for the applicable engine. For parallel connection of up to 20 extra VDO instruments. The instruments will automatically find their own parameter group from the databus. Maximum Easy Link cable length is 3 m. The following instruments are available:

• Tachometer/operating hours • Coolant temperature • Oil pressure

P0005054

• Oil temperature • Battery voltage Retaining collar

Retaining bracket

P0005053 P0005052

Extension cable, 3-pole, 1 m

P0005051

30

A

3-pin connector

B

3-pole connector

C

CIU wiring harness

7748542 10-2009


Instrument, analog (option) Refer to the System Information page 12 for the applicable engine. Tachometer Use Volvo Penta standard tachometer, graduations 0– 2,600 rpm. Setting code 14. Refer to installation instructions.

P0003961

Oil pressure gauge Use Volvo Penta oil pressure gauge, graduations 0– 10 bar (0–145 psi).

P0003961

Oil temperature gauge Use Volvo Penta oil temperature gauge, graduations 40–150 °C (104–302 °F).

P0003961

7748542 10-2009

31

Control System Installation, Connection Coolant temperature gauge Use Volvo Penta oil temperature gauge, graduations 40–150 °C (105–300 °F). Diagnostics switch Switch type: closing (NO), spring loaded. For reading fault codes, refer to the Control System Installation page 40 chapter. Contact, pre-heater Switch type: closing (NO), spring loaded. This contact activates the pre-heating. P0003961

32

7748542 10-2009


Synchronizing Engine Speed Synchronization/load distribution The system is adapted for GAC synchronization and load distribution. Use the EAM122 interface module when connecting to this system. When this system is used, voltage levels must be adjusted simultaneously with VODIA, according to the below. NOTICE! The EAM122 interface module is not sold by Volvo Penta. Contact a GAC (Governors of America Corporation) dealership.

A B C

A B C 0.7 V

2.75 V

4.8 V

P0005829

P0003964

A

Rpm control (GN/NO)

B

Rpm control (GN/SB)

C

Contact to (R/BL 1.5)

7748542 10-2009

A

Nominal revolutions +120 rpm

B


C

Nominal revolutions –120 rpm

33

Control System Installation, Parameter Setting

Parameter Setting Connection of special tool VODIA Connection of special tool VODIA

P0001169

Function It is possible to read and adjust parameters with the VODIA tool, part no.3838619, as described in the following pages. The VODIA tool is connected to the diagnostic outlet 6-pin connector located on the left side of the engine. Refer to the VODIA user directions for instructions.

34

7748542 10-2009


Adjustable parameters TAD1341GE, TAD1342GE, TAD1343GE, TAD1344GE, TAD1345GE, TAD1350GE, TAD1351GE, TAD1352GE, TAD1353GE NOTICE! Some parameters require special authorization.

Primary regulator mode

Indicated engine rpm inverted value

Selects the regulator to be used when the regulator contact is closed. Alternative modes: ”Isochronous” or ”Droop value” Preset mode: ”Isochronous”

Selects the regulator to be used when the regulator contact is closed. Alternative engine revolutions: 1500 rpm or 1800 rpm. Preset rpm: dependent on the specification ordered.

PTO regulator gradient is used

Maximum engine revolutions (CIU)

The gradient is defined either by a droop value in percent if the Regulator roop value parameter is equal to zero or Nm/rpm if the Regulator gradient parameter is equal to zero.

Potentiometer signal voltage on the CIU unit corresponding to nominal revolutions (1500/1800 rpm) plus +/- 90 rpm. Min. value: 1.90 V Max. value: 4.70 V Preset value: 4.50 V

Regulator droop value

Pre-heating for ignition

Selects the droop value magnitude to be used when droop value is activated (percent). Min. value: 0 % Max. value: 8 % Preset value: 4 %

Selects whether pre-heating and post heating is to be activated directly when the ignition is turned on. The pre-heating and post heating periods are dependent on coolant temperature. If the parameter is in ”Off” mode, pre-heating and post heating must be activated manually via the ignition lock or pre-heater button. Alternative modes: “Off” or “On” Preset mode: “Off”

Stop function

Lamp test

The CIU unit stop signal is energized during “operations” or “stop”. Preset mode: ”Stop”

This parameter determines if a lamp test is to be performed when the system is started. Alternative modes: “Off” or “On” Preset mode: “On”

Idling speed Setting idle revolutions. Min. value: 600 rpm Max. value: 1200 rpm Preset value: 900 rpm

7748542 10-2009

35


Adjustable parameters TAD1340VE, TAD1341VE, TAD1342VE, TAD1343VE, TAD1344VE, TAD1345VE NOTICE! Certain parameters require special authorization.

Regulator mode

Regulator gradient

Select if droop value is active. Alternative modes: “Off” or “No” Preset mode: ”No”

Determines the droop value to be used (gradient) Min. value: 10 Nm/revolution Max. value: 128 Nm/revolution Preset value: 25 Nm/revolution

Inverted regulator mode

Primary regulator mode

Select if droop value is to be active. Alternative modes: “No droop value” or “Variable droop value” Preset mode: “Fixed droop value”

Selects the regulator to be used when the regulator contact is closed. Alternative modes: ”Isochronous” or ”Droop value” Preset mode: ”Isochronous”

Idling speed

Idle voltage (CIU)

Setting idle revolutions. Min. value: 600 rpm Max. value: 900 rpm Preset value: 700 rpm

Throttle control input signal voltage to corresponding idle at the CIU unit. Min. value: 0.30 V Max. value: 1.90 V Preset value: 1.17 V

Voltage max. rpm (CIU)

Pre-heating for ignition

Throttle control input signal voltage to corresponding full throttle at the CIU unit. Min. value: 1.90 V Max. value: 4.70 V Preset value: 4.50 V

Selects if pre-heating is to be activated directly the ignition is turned on. If the parameter is in ”Off” mode, pre-heating and post heating must be activated manually via the ignition lock or pre-heater button. Alternative modes: “Off” or “On” Preset mode: “Off”

Stop function

CIU stop function

Preset mode: ”Stop”

The CIU unit stop signal is energized during “Operations” or “Stop”. Preset mode: ”Stop”

Lamp test This parameter determines if a lamp test is to be performed when the system is started. Alternative modes: “Off” or “On” Preset mode: “On”

36

7748542 10-2009


Alarm limits TAD1350GE, TAD1351GE, TAD1352GE Alarm threshold, high oil temperature A warning lamp is lit at this temperature. Min. value: 120 °C (248 °F) Preset value: 125 °C (257 °F) Max. value: 130 °C (266 °F) Alarm threshold, high coolant temperature A warning lamp is lit at this temperature. Min. value: 95 °C (203 °F) Preset value: 102 °C (216 °F) Max. value: 103 °C (217 °F)

Overspeed limit Percent above normal revolutions at which the overspeed warning is activated. Min. value: 0 % Preset value: 20 % Max. value: 20 %

Alarm limits TAD1340VE, TAD1341VE, TAD1342VE, TAD1343VE, TAD1344VE, TAD1345VE Alarm threshold, high oil temperature A warning lamp is lit at this temperature. Min. value: 120 °C (248 °F) Preset value: 125 °C (257 °F) Max. value: 130 °C (266 °F)

7748542 10-2009

Alarm threshold, high coolant temperature A warning lamp is lit at this temperature. Min. value: 95 °C (203 °F) Preset value: 102 °C (216 °F) Max. value: 103 °C (217 °F)

37


Engine protection TAD1341GE, TAD1342GE, TAD1343GE, TAD1344GE, TAD1345GE, TAD1350GE, TAD1351GE, TAD1352GE, TAD1353GE Oil temperature Determines whether engine protection is to be activated in respect of high oil temperature. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

Oil pressure Determines whether engine protection is to be activated in respect of low oil pressure. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

Coolant temperature Determines whether engine protection is to be activated in respect of high coolant temperature. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

Piston cooling pressure Determines whether engine protection is to be activated in respect of low piston cooling pressure. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

Coolant level Determines whether engine protection is to be activated in respect of low coolant level. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

Crankcase pressure Determines whether engine protection is to be activated in respect of high crankcase pressure. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

Charge air temperature Determines whether engine protection is to be activated in respect of high charge air temperature. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

Overspeed warning shutdown Determines whether engine protection is to be activated in respect of overspeed. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

Charge pressure Determines whether engine protection is to be activated in respect of high charge air pressure. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

38

7748542 10-2009


Engine protection TAD1340VE, TAD1341VE, TAD1342VE, TAD1343VE, TAD1344VE, TAD1345VE Oil temperature Determines whether engine protection is to be activated in respect of high oil temperature. A fault code is registered and the engine is shut down. TAD1650VE: a fault code is registered and an orange or red warning lamp is lit. Alternative modes: “Yes” or “No” Preset mode: “Yes” Coolant temperature Determines whether engine protection is to be activated in respect of high coolant temperature. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes” Coolant level Determines whether engine protection is to be activated in respect of low coolant level. A fault code is registered and the engine is shut down. TAD1650VE: a fault code is registered and an orange warning lamp is lit. Alternative modes: “Yes” or “No” Preset mode: “Yes” Charge air temperature Determines whether engine protection is to be activated in respect of high charge air temperature. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

Oil pressure Determines whether engine protection is to be activated in respect of low oil pressure. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes” Piston cooling pressure Determines whether engine protection is to be activated in respect of low piston cooling pressure. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes” Crankcase pressure Determines whether engine protection is to be activated in respect of high crankcase pressure. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes” ECU temperature Determines whether engine protection is to be activated in respect of high control unit temperature. A fault code is registered and an orange or red warning lamp is lit.

Charge pressure Determines whether engine protection is to be activated in respect of high charge air pressure. A fault code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Preset mode: “Yes”

7748542 10-2009

39

Control System Installation, Diagnostic Function

Diagnostic Function The diagnostic function monitors and controls that the EMS system functions normally. The diagnostic function has the following tasks:

• Detecting and locating disturbances • Reporting detection of disturbances • Providing guidance when fault tracing NOTICE! With the DCU:n it is possible choose the language that the inform-tion is presented in. If the diagnostic function detects a disturbance in the system, this is reported using fault codes via the instruments. Both active (unrectified) and passive (rectified) faults are stored in the control unit. Refer to the “Operation” heading for reading fault codes/fault messages. All fault codes and fault messages are found in the fault code list, with information about the reason, reaction and measures to be taken. Refer to Fault Code Register. NOTICE! All instruments are optional.

Effect on engine Engines are affected differently, depending on the severity of the fault discovered by the diagnostic function. A fault message in the form of a fault code is always generated when a malfunction is discovered by the diagnostic function. Engines are affected differently, depending on the severity of the fault:

• The engine is not affected • Engine goes to idle • Engine torque is restricted to a certain amount • Engine is stopped

40

7748542 10-2009

Control System Installation, Diagnostic Function

Active and Inactive Faults Active faults At the same time, the fault is stored in the control unit memory. When the fault has been attended to and the ignition is switched off and on again, the fault disappears as active.

Inactive faults •

DCU – the fault is indicated as passive

•

CIU – the diagnostic lamp goes out

•

DU – the fault message disappears (inactive faults cannot be read out)

•

“Easy Link” – the lamp on the alarm panel goes out

DCU (Display Control Unit) •

text !! ENGINE WARNING !! shown on the display.

CIU (Control Interface Unit) •

the diagnostic lamp starts to flash.

•

”Easy Link” instrument - the relevant lamp on the alarm panel lights up - after the diagnostic button has been pressed, the fault code is shown as text on the tachometer display.

DU (Display Unit) •

Either WARNING! or ALARM STOP (a buzzer sounds) will be shown on the display, depending on the severity of the fault.

•

Fault codes can also be read off using the VODIA tool. For instructions, see “VODIA User’s Guide”.

Operation When a malfunction has occurred and the diagnostic system has generated one or more fault codes, these are read out differently depending on the equipment used. Please refer to “Fault code messages”. If the system indicates that a fault code has been set: 1 Cut engine speed to idle, or shut the engine off. 2 For DCU/DU Read the fault code from the display, please refer to Reading fault codes via the DCU or Reading fault codes via the DU. For CIU press the diagnostic button and read the fault code, by observing the flashing of the diagnostic lamp. Refer to Reading fault codes via the diagnostic lamp, CIU.

Reading fault codes via the DU (Display Unit) Depending on the severity of the fault the text, either WARNING! or ALARM STOP (a buzzer sounds) will be shown on the display 1 Press any button to come to the fault list. The fault list shows operation hours and fault message. 2 Look up the fault code in Fault Code Register and take the recommended measures. 3 Press on ACK to acknowledge the fault code. The display background will change color (the buzzer stops sounding). 4 Press on EXIT to leave the fault list.

3 Look up the fault code in the Fault Code Register chapter and take the recommended measures.

7748542 10-2009

41

Control System Installation, Diagnostic Function Reading fault causes via the DCU (Display Control Unit) When a fault code is set, the following text is shown on the display: !! ENGINE WARNING !! alternated withPress SEL for information. Read the fault code as follows: 1 Press SEL-button to come to the fault list. The fault list shows: -Operation hours -Fault message -Active/inactive 2 Look up the fault code in theFault Code Register chapter and take the recommended measures.

Reading fault codes via an “Easylink” instrument When the system has discovered a malfunction, this is reported by the diagnostic lamp which starts to flash. 1 Press the diagnostic button. The fault code is shown as text on the tachometer display. 2 Look up the fault code in the Fault Code Register chapter and take the recommended measures. 3 When the fault has been rectified, the fault code disappears from the display and the diagnostic lamp goes out.

3 Press ESC-button to leave the fault list. NOTICE! To enter the fault list when no fault code has been set, press the SEL button and select Diagnostics from the menu.

Reading fault codes via the diagnostic lamp on the instrument panel, CIU When the system has discovered a malfunction, the diagnostic lamp starts to flash. If the diagnostic button is depressed and then released, a fault code is flashed out. The fault code consists of two groups of flashes, separated by a pause of two seconds. A fault code is obtained by counting the number of flashes in each group Example: paus = Fault Code 2.4 The fault code is stored and can be read as long as the malfunction remains. You can find information about cause, reaction and actions in the Fault Code Register chapter. Read the fault code as follows:

Erasing fault codes Fault codes must be erased by an authorized Volvo Penta workshop by means of the VODIA tool.

1 Press the diagnostic button. 2 Release the diagnostic button and make a note of the fault that is flashed out. 3 Repeat items 1-2. A new fault code is flashed ou tif more are stored. Repeat until the first fault code is repeated. NOTICE! When the first fault code reoccurs, all the fault codes have been read. If the diagnostics button is depressed after the fault has been corrected and the fault code deleted, the code 1.1, No fault, will be shown.

42

7748542 10-2009

Control System Installation, Fault Code Register

Fault Code Register CAUTION! Read through the safety advice before starting any work. The fault codes below comprise: -

a fault text message displayed when a DCU or DU is installed.

-

a flash code, e.g. 5.4, read off from the diagnostics lamp; refer to Control System Installation page 40

-

a fault code, e.g. PID 45, read off from the VODIA tool.

For references to sleeves in electrical connectors, refer to System Information page 12.

No fault (Code 1.1) Cause There are no active faults.

Reaction

Remedy

Water in Fuel (Code 2.1, PID/SPN 97) Cause • Water in fuel

Reaction • None

Remedy • Empty the primary fuel filter

Coolant Level (Code 2.2, PID/SPN 111) Cause • Low coolant level

Reaction • Engine control module reduces engine power (unless the protection has been shut off with the VODIA diagnostic tool)

Remedy • Check the coolant level •

Check coolant level monitor function

Coolant Level Sensor (Code 2.3, PID/SPN 111) Cause • Short circuit to positive (+) •

Reaction • None

Fault in sensor

Remedy • Check that the coolant level sensor cable is not damaged •

Check coolant level sensor function

Flywheel Speed Sensor (Code 2.4, SID 22/SPN 637) Cause • No signal •

Abnormal frequency

•

“Intermittent” signal from the sensor

•

Fault in sensor

7748542 10-2009

Reaction • Engine is very difficult to start and runs roughly when it starts

Remedy • Check that the sensor connector is correctly installed •

Check that the engine speed sensor cable is not damaged

•

Check that the engine speed sensor is correctly installed in the flywheel housing

•

Check engine speed sensor function

43


Camshaft Drive Speed Sensor (Code 2.5, SID21/SPN 636) Cause • No signal •

Abnormal frequency

•

Fault in sensor

Reaction • Engine takes longer to start than normal. Engine runs normally when running

Remedy • Check that the engine speed sensor connector is correctly installed •

Check that the engine speed sensor cable is not damaged

•

Check that the engine speed sensor is correctly installed in the upper timing gear cover.

•

Check engine speed sensor function.

Engine Speed (Code 2.6, PID/SPN 190) Cause • Engine speed too high

Reaction • None

Remedy • After the engine has stopped, look for the reason for the high speed

Speed Potentiometer Connected to CIU (Code 2.8, PPID 132/SPN 91, 608,) Cause • Shorted to plus (+) or minus (-) •

Reaction • Engine goes to idle •

Speed feezes

Fault in sensor

Remedy • Check that the potentiometer has been connected correctly •

Check that the cable harness to the potentiometer has not been damaged

•

Check the potentiometer function

Indicator for Water in Fuel (Code 2.9, PID/SPN 97) Cause • Short circuit •

Open circuit

•

Fault in indicator

Reaction • None

Remedy • Check the indicator cables for breaks and short circuits •

Check indicator function. Change indicator as necessary

Oil Pressure Sensor (Code 3.1, PID/SPN 100) Cause • Short circuit to positive (+) or earth (ground) (–) •

44

Open circuit

Reaction • None

Remedy • Check that the oil pressure sensor cable is not damaged •

Check that the oil pressure sensor is correctly connected

7748542 10-2009


Boost Temperature Sensor (Code 3.2, PID/SPN 105) Cause • Short circuit to positive (+) or earth (ground) (–) •

Reaction • None

Open circuit

Remedy • Check that the boost temperature sensor connector is correctly installed •

Check that the boost temperature sensor cable is not damaged

•

Check that the boost temperature sensor is correctly installed

•

Check boost temperature sensor function

Coolant Temperature Sensor (Code 3.3, PID/SPN 110) Cause • Short circuit to positive (+) or earth (ground) (–) •

Reaction • Preheating is also activated when the engine is hot

Open circuit

Remedy • Check that the coolant temperature sensor connector is correctly installed •

Check that the coolant temperature sensor cable is not damaged

•

Check that the coolant temperature sensor is correctly installed

•

Check coolant temperature sensor function

Boost Pressure Sensor (Code 3.4, PID/SPN 102/106) Cause • Short circuit to positive (+) or earth (ground) (–) •

Open circuit

7748542 10-2009

Reaction • Engine smokes more than normally during acceleration/ load increase

Remedy • Check that the boost pressure sensor connector is correctly installed •

Check that the boost pressure sensor cable is not damaged

•

Check that the boost pressure sensor is correctly installed

•

Check boost pressure sensor function

45


Boost Pressure Sensor (Code 3.5, PID/SPN 106) Cause • High charge pressure

Reaction • Engine power is reduced or engine stops.

Action • Check that the charge air pressure sensor connector is correctly installed •

Check that the charge air pressure sensor cable is not damaged

•

Check that the charge air pressure sensor is correctly installed

•

Check charge air temperature sensor function

Fuel Pressure Sensor (Code 3.6, PID/SPN 94) Cause • Short circuit to positive (+) or earth (ground) (–). •

Reaction • None

Open circuit.

Remedy • Check that the fuel pressure sensor connector is correctly installed. •

Check that the fuel pressure sensor cable is not damaged.

•

Check that the fuel pressure sensor is correctly installed.

•

Check fuel pressure sensor function.

Oil Temperature Sensor (Code 3.7, PID/SPN 175) Cause • Shorted to plus (+) or minus (-) •

Reaction • None

Break

Remedy • Check that the cable harness to the oil temperature sensor has not been damaged •

Check that the oil temperature sensor has been connected correctly

Fuel Pressure (Code 3.8, PID/SPN 94) Cause • Low supply pressure

Reaction • None

Remedy • Check if it is possible to build up pressure with the hand pump •

Check the fuel filter

•

Check the fuel pre-filter

Battery Voltage, EMS (Code 3.9, PID/SPN 158) Cause • Faulty alternator •

46

Faulty battery, battery cables

Reaction • None

Remedy • Check the supply voltage from the control unit

7748542 10-2009


Start output/Start motor relay (Code 4.6, PPID 3/ SPN 677) Cause • Shorted to plus (+) or minus (-) •

Reaction • The engine cannot be started •

Activated for too long

The engine starts immediately when ignition is turned on

Remedy • Check that connections to the ignition key/start panel have not been damaged •

Check that the cable harness to the ignition key/sart panel has not been damaged

Stop Input EMS (Code 4.8, PPID 6/SPN 970) Cause • Short circuit to negative (-) •

Open circuit

Reaction • Engine can only be stopped with the auxiliarystop

Remedy • Check that the starter switch connections are not damaged

Starter Input CIU (Code 5.2, PPID 4/SPN 520194) Cause • Shorted to minus (-) •

Activated for too long

Reaction • The engine cannot be started •

The engine starts immediately when ignition is turned on

Remedy • Check that connections to the ignition key/start panel have not been damaged •

Check that the cable harness to the ignition key/start panel has not been damaged

Stop Input CIU (Code 5.3, PPID 6/SPN 52095) Cause • Short circuit to negative (-) •

Open circuit

•

Activated for too long time

Reaction • Engine can only be stopped with the auxiliary stop (AUX STOP) on engine •

Remedy • Check that the starter switch connections are not damaged •

Engine stops. A fault code is displayed for 40 seconds and the engine can not be started during this time. When a fault code is active, the engine can be started but not stopped

Check that the ignition switch cable is not damaged

Preheating Relay (Code 5.4, PID 45/SPN 626) Cause • Short circuit to positive (+) or earth (ground) (–). •

Open circuit.

Reaction • Preheating can not be activated. •

Preheating is constantly connected.

Remedy • Check that the relay input cable is not damaged. •

Check relay function.

Air Filter Pressure (Code 5.5, PID/SPN 107) Cause • Too large pressure drop across filter

7748542 10-2009

Reaction • Less good response from engine

Remedy • Check the air filter

47


Air Filter Sensor (Code 5.6, PID/SPN 107) Cause • Shorted to plus (+) or minus (-) •

Reaction • None

Break

Remedy • Check that the air filter sensor contact is correctly installed •

Check that the cable harness to air filter sensor has not been damaged

•

Check the air filter sensor functionality

Oil Level (Code 5.7, PID/SPN 98) Cause • Oil level to low

Reaction • None

Remedy • Check the oil level

Oil Temperature (Code 5.8, PID/SPN 175) Cause • Oil temperature is too high

Reaction • The engine control module limits engine output(unless protection has been turned off with thediagnosis tool VODIA)

Remedy • Check the oil level •

Check the oil temperature

•

Check the oil temperature sensor function

Oil Level Sensor (Code 5.9, PID/SPN 98) Cause • Shorted to plus (+) or minus (-) •

Reaction • None

Break

Remedy • Check that the cable harness to the oil level sensor has not been damaged •

Check the oil level sensor function

Coolant Temperature (Code 6.1, PID/SPN 110) Cause • Coolant temperature is too high



Check the charge air cooler (cleanliness)

•

Check if there is air in the cooling system

•

Check the pressure cap on the expansion tank

•

Check coolant temperature sensor function

•

Check thermostat function

Boost Temperature (Code 6.2, PID/SPN 105) Cause • Boost temperature is too high

48



Check the charge air cooler (cleanliness)

•

Check boost temperature sensor function

•

Check the function of the thermostat

7748542 10-2009


Data Link (CAN), CIU (Code 6.4, SID 231/SPN 639) Cause • Faulty data link (CAN), , CIU

Reaction • Instruments and warning lamps stop working

Remedy • Check that the 8-pin connector is not damaged •

Check that the cables between the CIU and the engine management unit are not damaged

Data Link (CAN), EMS 2 (Code 6.5, SID 231/SPN 639/2017/PSID 201) Cause • Internal fault in control module

Reaction • Engine not operating: engine can not be started. Engine operating: engine idles and can only be stopped with the auxiliary stop (AUX-stop)


Check that the cables between the CIU and the engine management unit are not damaged

•

Check that sleeves 11 and 12 in the connector on the CIU are not damaged

Oil Pressure (Code 6.6, PID/SPN 100) Cause • Oil pressure is too low


Remedy • Check oil level •

Check that the air filter is not blocked

•

Check system pressure valves and safety valves in the oil system

•

Check oil pressure sensor function

Piston Cooling Pressure (Code 6.7, PPID 8/SPN 520192) Cause • Piston cooling pressure is too low

Reaction • Engine stopped

Remedy • Check that the oil pressure in the engine exceeds175 kPa (25.4 psi)

Piston Cooling Pressure Sensor (Code 6.8, PPID 8/SPN 520192) Cause • Shorted to plus (+) or minus (-) •

Break

7748542 10-2009

Reaction • None

Remedy • Check that the piston cooling pressure sensor contact is correctly installed •

Check that the cable harness to the piston cooling pressure sensor has not been damaged

•

Check the piston cooling pressure sensor functionality

49


Battery Voltage, CIU (Code 6.9, PID/SPN 158) Cause • Short circuit to negative (-) •

Faulty alternator

•

Faulty battery, battery cables

Reaction • Problems in engine starting

Remedy • Check the supply voltage from the control unit •

Check the batteries

•

Check the alternator

•

Check the 8-pin contact

SInjector, Cylinder #1 (Code 7.1, SID 1/SPN 651) Cause • Electrical fault •

Faulty compression or injector

Reaction • Engine runs on 5 cylinders •

Abnormal sound

•

Reduced performance

Remedy • Check that the injector cables are not damaged •

Check that the injector connections are not damaged

•

Check fuel supply pressure

•

Check the valve clearance

•

Do a compression test and check cylinder #1

Injector, Cylinder #2 (Code 7.2, SID 2/SPN 652) Cause • Electrical fault •



Abnormal sound

•

Reduced performance



•


•


•



50



Abnormal sound

•

Reduced performance



•


•


•


7748542 10-2009





Abnormal sound

•

Reduced performance



•


•


•





Abnormal sound

•

Reduced performance



•


•


•





Abnormal sound

•

Reduced performance



•


•


•


Crankcase Ventilation Pressure (Code 7.7, PID/SPN 153) Cause • Crankcase ventilation pressure too high

7748542 10-2009

Reaction • The engine is shut down (if the protection has notbeen shut off by the parameter tool)

Remedy • Check whether the crankcase ventilation is blocked •

Check whether cylinder liners, pistons or piston rings are worn or damaged

51


Crankcase Ventilation Pressure Sensor (Code 7.8, PID/SPN 153) Cause • Shorted to plus (+) or minus (-) •

Reaction • None

Break

Remedy • Check that the crankcase ventilation pressure sensor contact is correctly installed •

Check that the cable harness to the crankcase ventilation pressure sensor has not been damaged

•

Check that the crankcase ventilation pressure sensor correctly installed

•

Check crankcase ventilation pressure sensor function

Air Temperature Sensor, Inlet (Code 7.9, PID/SPN 172) Cause • Shorted to plus (+) or minus (-) •

Reaction • None

Break

Remedy • Check that the air temperature sensor contact is correctly installed •

Check that the cable harness to the air temperature sensor has not been damaged

•

Check that the air temperature sensor is correctly installed

•

Check the air temperature sensor functionality

Injection Pressure (Code 8.3, PID/SPN 164) Cause • Fault in fuel supply •

Fault in fuel pump

•

Fault in harness

•

Fault in sensor

Reaction • Warning lamp lights up •

Control unit reduces engine power

Remedy • Check harness •

Check sensor

•

Check fuel filter

•

Check fuel pump

Injection Pressure, Regulator (Code 8.3, SID 42/SPN 679) Cause • Faulty cables •

Faulty actuator

•

Fault in MPROP

Reaction • Control unit reduces engine power

Remedy • Contact an authorized Volvo Penta workshop

Pressure in Distribution Manifold (Code 8.3, PSID 96/SPN 1239) Cause • Leakage in the high pressure fuel system •

52



Leakage in the high pressure supply pipe to the injector

7748542 10-2009


Pressure Valve (Code 8.3, PSID 97/SPN 679) Cause • Leakage in the PRV (Pressure Release Valve) •

The PRV stuck closed

•

The PRV stuck open



ECU Temperature (Code 8.4, PPID 55/SPN 1136) Cause • Control unit too hot, incorrect assembly •

Reaction • None

Remedy • Check the control unit installation. Recommended ambient temperature is 50°C (122°F)

Electrical fault, damaged sensor

TAD1350GE, TAD1351GE, TAD1352GE, TAD1353GE

Internal EGR (Code 8.5, PPID 19/SPN 2791) Cause • Fault in cable harness (boost pressure sensor) •

Reaction • Engine control module reduces engine power

Mechanical fault on the IEGR

Remedy • Check cable harness (boost pressure sensor) •

Check the IEGR

•

Contact a Volvo Penta authorized workshop

Preheating Sensor (Code 8.6, SID 70/SPN 729) Cause • Fault in cable harness •

Fault in preheating relay

Reaction • Preheating can not be activated

Remedy • Check the cable harness •

Check the preheating relay

Faulty data link (J1587) (Code 9.2, SID 250/SPN 608) Cause • Faulty data link

Reaction • None


Check that the cables between the CIU/DCU and the engine management unit are not damaged

Power Supply to Sensor (Code 9.3, SID 211/232, SPN 1079/1080) Cause • Shortcut •

Fault in sensor

7748542 10-2009

Reaction • Faulty values in oil pressure and boost pressure sensors •

Fault code for oil pressureand boost pressure sensor

•

Low engine output

•

The instrument shows zero oil pressure and boost pressure

Remedy • Check that the cable harness to oil pressure and boost pressure sensor has not been damaged •

Check oil pressure and boost pressure sensors

53


Data Set Memory EEPROM, CIU (Code 9.8, SID 253/SPN 630) Cause • Internal fault in control module •

Reaction • Engine does not start

Remedy • Re-program the control module.

Programming faulty

Fault in Control Unit, CIU (Code 9.8, SID 254/SPN 629) Cause • Faulty EEPROM, CIU

Reaction • CIU returns to factory setting

•

Faulty flash memory, CIU

•

Engine goes to idle

•

Fault in control module, CIU

•

Engine can not be started

Remedy • Re- program the unit

Memory Fault EMS (Code 9.9, SID 240/SPN 628) Cause • Memory fault in engine management system

Reaction • Engine might not start

Remedy • Re-program the unit

Data Set Memory EEPROM, EMS (Code 9.9, SID 253/SPN 630) Cause • Internal fault in control module •

Reaction • Engine does not start

Internal fault in control module

Remedy • Re-program the control module. If the fault remains, change the control module

Control Module EMS (Code 9.9, SID 254/SPN 629) Cause • Internal fault in control module

Reaction • Engine misfires •

Remedy • Change engine control unit

Engine does not start

Wastegate (SID 32/SPN 1188) Cause • Short circuit to positive (+) or negative (-) •

Open circuit

•

Wastegate damaged mechanically

Reaction • Warning lamp lights up •

Engine control unit limits engine power

Remedy • Check that the wastegate connector is properly mounted •

Check that the wiring to the wastegate is not damaged

•

Check that the wastegate is correctly mounted

•

Check the wastegate

Fan, rpm sensor (PID 26/SPN 975) Cause • Open circuit

54

Reaction • Warning lamp lights up

Remedy • Check that the fan actuator is properly mounted •

Check that the wiring to the fan actuator is not damaged

•

Check that the fan actuator is correctly mounted

•

Check the fan actuator

7748542 10-2009


Fan actuator (SID 33/SPN 975) Cause • Short circuit to positive (+) or negative (-)

Reaction • Warning lamp lights up

Remedy • Check that the fan actuator is properly mounted

•

Open circuit

•

•

Fan actuator damaged mechanically

Check that the wiring to the fan actuator is not damaged

•

Check that the fan actuator is correctly mounted

•

Check the fan actuator

7748542 10-2009

55

Alphabetical index Adjustable parameters.................................... 35, 36 Alarm limits.............................................................. 37 CIU.................................................................... 20, 23 Connection.............................................................. 17 Connection of special tool VODIA........................... 34 Control System Installation...................................... 17 DCU......................................................................... 26 Diagnostic Function................................................. 40 EMS........................................................................... 5 Engine protection.............................................. 38, 39 Fault Code Register.............................................. 43 General................................................................... 17 In- and out signals................................................... 8 Installation Tools and Documentation....................... 4 Instruments................................................................ 9 Instruments.............................................................. 30 Location of Sensors.............................................. 10 Other Special Equipment........................................ 4 Parameter Setting.................................................. 34 Power supply........................................................... 18 Rpm-potentiometer............................................... 28 Safety Information................................................... 2 Special Tools............................................................. 4 Synchronizing Engine Speed.................................. 33 System Information................................................... 5 Warning and Indication Lamps............................ 29 Wiring Diagram........................................................ 12

7748542 10-2009

57

Report form Do you have any comments or complaints about this manual? Please take a copy of this page, write your comments on it and send it to us. The address is at the bottom. We would appreciate it if you were to write in English or Swedish.

From: ............................................................................ ...................................................................................... ...................................................................................... ......................................................................................

Refers to publication: ............................................................................................................................................. Publication no: ............................................................... Date of issue: .................................................................

Suggestion/Motivation: .......................................................................................................................................... .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. .............................................................................................................................................................................. ..............................................................................................................................................................................

Date: ................................................................ Name: ..............................................................

AB Volvo Penta Teknisk Information Avd. 42200 SE-405 08 Göteborg Sweden

7748542 English 10-2009

VOLVO 7748542_US_ Installation EMS 2 - D13

Recommend Documents