Sie sind auf Seite 1von 62

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

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.

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.

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-4800
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.

AMP 539 968


Removal tool, 1.5 mm pin width

P0003809

AMP 726 519


Removal tool, 0,06 inch pin width

P0003811
P0003813

AMP 929 039


Removal tool, 2.8 mm pin width

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
engines left side.

7748542 10-2009

System Information, EMS

CIU (Control Interface Unit)


The CIU is a translator between the CAN bus and the
customers 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

7748542 10-2009

System Information, EMS

Fuel control
The engines fuel requirement is analyzed up to 100
times per second (depending on engine rpm). The
engines 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 injectors mechanically operated pump
plunger. When sufficient pressure has developed, fuel
is injected into the cylinder via the unit injectors 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 Volvos
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

System Information, EMS

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

7748542 10-2009

System Information, EMS

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

System Information, EMS

Location of Sensors
2

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

GN/R

SB

18

17

SB

R
2P 1

25

P2

12

30

SB 4
R1

SB 2

28 27 23 14

1P

15

21

10

SB

SB

SB

12 3 4 5 6 7

CAN 2

GR/OR

SB

R 1,0

1
3 P2

26

R 3
SB
1

BN/OR
GR/GN

32

BC AE D F

P4

21
n

14

21
n

13

Y 1,0
Y 1,0

SB 1,0

GN

BL/GB
Y 1,0

31

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

60 61

59 62

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

BN 1,0

R 1,0

SB

23

Y 1,0

SB 1,0

GN
BL
OR/SB
GB/SB

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

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

1 2345
B+
B-

20

18

R 25

SB 25

7 8

AB
1 2 3 4 5 6

10

R 25

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

R/W
Y/SB
R 2,5

11

30

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

System Information, EMS

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 mm 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 (TAD13501353GE only)
30 Control unit, EMS 2.2
31 Wastegate Valve
32 Electric fan

7748542 10-2009

13

System Information, EMS

CIU (Control Interface Unit)


CIU (Control Interface Unit)

14

7748542 10-2009

System Information, EMS

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

System Information, EMS

DCU (Display Control Unit)


12345678 8
Y/W

GR/Y

SB 2,5

R 2,5

R/BL 2,5

BL 2,5

W/SB

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

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

VO

R/Y

12345678 9
1 2 3 4 5 6 7 8 10

SB/Y

R/BL

SB

GN/R

GN/Y

GN/SB

10

SB/VO

11

SB/GR

12

SB/W

1
3
2

6
7

P0004305

1 Stoppkontakt

Kabelfrger

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 Gngindikering
8 Deutsch 8-poligt kontaktdon, engine interface
9 Deutsch 8-poligt kontaktdonshylsa, engine interface
10 Termineringsmotstnd 120
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

Control System Installation, Connection

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

Control System Installation, Connection

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

Control System Installation, Connection

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

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

Control System Installation, Connection

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: 0.31.9 V (preset
value 1.17 V)
Nominal revolutions plus 90 rpm: 1.94.7 V (preset
value 4.5 V)

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

Control System Installation, Connection

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

Control System Installation, Connection

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

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

Engine system voltage start current (control unit) is 10


A. Ensure that other components in the installation are
dimensioned for this current load.

P0003965

Stop contact

ON contact

Start lock

Pre-heating contact

Start lock positions

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

Pre-heating

Start

Batt +

15 start lock

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

Control System Installation, Connection

DCU

C
A

P0005826

8-pin connector from the engine wire harness.

3-pin Deutsch connector, Easy Link instrument

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

Control System Installation, Connection

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: 010 V (preset
value 1 V)
Nominal revolutions plus 120 rpm: 010 V (preset
value 9 V)
It is possible to invert the signal; see diagram.

C
P0005824

C
1V

5V

9V
P0005825

1V

5V

Nominal revolutions + 120 rpm

Nominal revolutions + 120 rpm

Nominal revolutions (1500/1800 rpm)

Nominal revolutions (1500/1800 rpm)

Nominal revolutions - 120 rpm

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: 010 V (preset value 9V)


Min. potentiometer value: 010 V (preset value 1V)

28

7748542 10-2009

Control System Installation, Connection

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

Control System Installation, Connection

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

3-pin connector

3-pole connector

CIU wiring harness

7748542 10-2009

Control System Installation, Connection

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 (0145 psi).

P0003961

Oil temperature gauge


Use Volvo Penta oil temperature gauge, graduations
40150 C (104302 F).

P0003961

7748542 10-2009

31

Control System Installation, Connection


Coolant temperature gauge
Use Volvo Penta oil temperature gauge, graduations
40150 C (105300 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

Control System Installation, Connection

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

Rpm control (GN/NO)

Rpm control (GN/SB)

Contact to (R/BL 1.5)

7748542 10-2009

Nominal revolutions +120 rpm

Nominal revolutions (1500/1800 rpm)

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

Control System Installation, Parameter Setting

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

Control System Installation, Parameter Setting

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

Control System Installation, Parameter Setting

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

Control System Installation, Parameter Setting

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

Control System Installation, Parameter Setting

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 Users
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

Control System Installation, Fault Code Register

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

Control System Installation, Fault Code Register

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

Control System Installation, Fault Code Register

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

Control System Installation, Fault Code Register

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

Control System Installation, Fault Code Register

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

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 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

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 the charge air cooler


(cleanliness)

Check boost temperature


sensor function

Check the function of the thermostat

7748542 10-2009

Control System Installation, Fault Code Register

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)

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

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

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

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

Control System Installation, Fault Code Register

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

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 #2

Injector, Cylinder #3 (Code 7.3, SID 3/SPN 653)


Cause
Electrical fault

50

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 #3

7748542 10-2009

Control System Installation, Fault Code Register

Injector, Cylinder #4 (Code 7.4, SID 4/SPN 654)


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 #4

Injector, Cylinder #5 (Code 7.5, SID 5/SPN 655)


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 #5

Injector, Cylinder #6 (Code 7.6, SID 6/SPN 656)


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 #6

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

Control System Installation, Fault Code Register

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

Reaction
Control unit reduces engine
power

Remedy
Contact an authorized Volvo
Penta workshop

Leakage in the high pressure


supply pipe to the injector

7748542 10-2009

Control System Installation, Fault Code Register

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

Reaction
Control unit reduces engine
power

Remedy
Contact an authorized Volvo
Penta workshop

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 50C
(122F)

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

Remedy
Check that the 8-pin connector is not damaged

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

Control System Installation, Fault Code Register

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

Control System Installation, Fault Code Register

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 Gteborg
Sweden

7748542 English 10-2009