Installation I

EMS 2 1(1)
Industrial engines

TAD650VE, TAD660VE, TAD750VE, TAD760VE

Advance Copy
This publication is an Advance Copy and can not be ordered as printed copy. All data and all descriptions
in this Advance Copy are based on verified information that was available at the given issue
date for this publication. All non verified information has been left out. This publication
may not have complete data or descriptions. References to publication numbers, tool numbers,
part numbers etc., may not be valid and active in order systems before the final release
of this publication. The final release will keep the same publication number as this Advance Copy
and can be ordered as printed copy. The final release will supersede this Advance Copy in any and
all forms or media.
 Installation
EMS 2

TAD650VE, TAD660VE
TAD750VE, TAD760VE

Contents

Safety rules ............................................................ 2 DCU ...................................................................... 24

General .............................................................. 24
Special tools ......................................................... 4 Connection ......................................................... 25

General information .............................................. 6 Parameter setting ................................................ 26

The EMS 2-system .............................................. 6
Component location ............................................. 9
Voltage feed 24 V .............................................. 10
Electrical diagram EMS2 .................................... 11
Wiring diagram CIU ............................................ 12
Wiring diagram DCU ........................................... 13
Connection of the VODIA parameter tool ........... 26
Operation, VODIA .............................................. 26
Adjustable parameters ....................................... 27
Engine protector ................................................. 28
Fault tracing ........................................................ 29

Installing the control unit ................................... 14 Diagnostic function ............................................. 30

CIU ....................................................................... 19 Fault codes .......................................................... 33

General .............................................................. 19
Connection ......................................................... 20 Reference to service bulletins ............................ 43
Engine control .................................................... 20
Warning and indication lamps ............................. 20
Instruments ........................................................ 22
Other .................................................................. 23

2005 AB VOLVO PENTA

We reserve the right to make changes or modifications.
Printed on environmentally compatible paper.
Safety rules

Safety rules

Introduction
This installation book contains the information needed
to install and function check the EMS 2 system (elec-
tronic control of the injection system).
Read the instruction book carefully before you start in-
stallation. If the installation is done in a faulty manner,
this can cause personal injury or damage to property
and machinery.
If you do not understand, or are unsure about anything
in this instruction book, please ask your Volvo Penta
dealer for assistance.
Important!
The following special warning symbols occur in this
book and on the engine.
WARNING! Warns for the risk of personal injury,
property damage or that a mechanical fault can
occur if the instructions are not followed.
IMPORTANT! Is used to call attention to things
which could cause damage or malfunctions to
product or property.

NOTE! Is used to call attention to important informa-

tion, to facilitate work processes or operation.
Installation
This installation manual is only intended for profes- Below is a summary of the risks involved and safety
sional use. precautions you should always observe or carry out
when installing and calibrating the EMS 2 system.
The installation manual is intended to be used togeth-
er with the relevant engine instruction book. Before electric welding is done, the connector
Volvo Penta declines all responsibility for personal in- on the EMS system must be disconnected.
jury or property damage which might occur as a result Disconnect the engine from system voltage by
of not following the installation advice, or if the work is turning off the main switch.
not done by professional personnel. Disconnect the cable connectors from the con-
trol unit.
The installer is responsible for ensuring that the sys- Reconnect the EMS 2 control module terminal
tem operates in the manner described in the instruc- when the electric welding is finished and the elec-
tion book. tric welding equipment has been disconnected.
Modifications of the cable harness that are sup-
plied together with the engine is not allowed. Be careful, watch out for the moving compo-
nents of the engine during function testing and
in operation. Approaching the engine during op-
eration entails a risk of personal injury. Remem-
ber that loose clothes or long hair can catch on
rotating components and cause severe injury.
Work methods
These instructions are intended to be used by suitably
qualified personnel. In these instructions, these
person(s) is/are referred to as the installer(s).
Also refer to the specific engine instruction book for
relevant information when necessary, and in particular
for information relating to safety and engine operation.
Work must be performed by Volvo Penta workshops
or other authorized, well equipped workshop, by quali-
fied and experienced personnel.

2

Never do any work on an engine which just
hangs from a lifting device (crane etc.).
The engine must not be run in areas where ex-
plosive material or any gases are stored.
Only start the engine in a well-ventilated area. If
the engine is run in a confined space, make
sure that the crankcase ventilation and exhaust
gases can be led away from the workplace.
The battery lockers must never be exposed to
open flames or sparks. Never smoke close to
the batteries. The batteries generate hydrogen
gas when charged, which can form an explosive
gas when mixed with air. This gas mixture is
very flammable and highly explosive. A spark,
which can be caused by incorrect battery con-
nection, can cause a single spark which is suffi-
cient to cause an explosion with resulting dam-
age. Do not shift the connections when attempt-
ing to start the engine (spark risk) and do not
lean over any of the batteries. Please refer to
the advice in the instruction book.
Safety rules
Always ensure that the + (positive pole) and
(negative pole) are securely connected to their
appropriate terminals on the battery. If the bat-
teries are wrongly connected, this can cause se-
vere damage to the electrical equipment. Please
refer to the wiring diagram in the engine instruc-
tion book.
Always use goggles when charging and handling
batteries. Battery electrolyte contains sulfuric
acid, which is highly corrosive. If battery acid
comes into contact with your skin, wash it off at
once with a lot of soap and water, and then get
medical help. If battery acid comes into contact
with your eyes, flush your eyes at once (prefera-
bly with an eye shower) with a lot of clean water,
and then get medical help at once.
3
Special tools

Special tools

9510060
3838619

3838619 VODIA, complete with cable harness. 9510060-8 Multimeter

See VODIA Users Guide for ordering
separate parts.

4
 Special tools

Other special equipment

The tools below are intended for use in work on the cable harnesses of the engine. The tools are not included in
Volvo Pentas range, they must be ordered from a local AMP or Deutsch dealer. If you experience problems in
contacting a dealer, please contact Volvo Penta Quality Action Center for advice.

HDT-48-00 AMP 539,968 AMP 726,534 AMP 726 519

AMP 929,039 AMP 239,635 AMP 825,514 GHW 50000 017 586

Deutsch connectors 4.8 mm and 6.3 mm cable clamps. Tongues and

HDT-48-00 Crimping tool socket terminals
AMP connector (42-pin CIU, 62-pin EMS, 2- and 825 514-1 Crimping tool
3-pin Bosch etc.) GHW connector (relay box)
539 968-1 Removal tool, 1,5 mm pin width 50000 017 586 Disassembly tool 4.8 mm
726 534-1 Removal tool, 1,6 mm pin width pin width
726 519-1 Removal tool, 2.8 mm pin width
929 039-1 Removal tool, 2.8 mm pin width
239 635-1 Crimping tool
825 514-1 Crimping tool

5
General information

General information

EMS 2 - Engine Management System

EMS 2 is an electronic system with CAN communication (Controller Area Network) for diesel engine control. The
system has been developed by Volvo and includes fuel control and diagnostic 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 communica-
tions interface consisting of a CAN link and a serial link.

CAN - Controller Area Network

The J1939 CAN link is responsible after all communi-
cation between the engine control unit (EMS 2) and a
communication interface (such as CIU/DCU), except
for diagnostics. Diagnostics are managed by the so-
called J1708/J1587 link. The CAN link is much faster
than the J1708/J1587 link and has been designed to
connect to other components that support the SAE
J1939 protocol, such as instrument panels and trans-
missions.
If a fault develops on the CAN link, signals for the en-
gine speed potentiometer, and the start and stop
knobs are taken over by the J1708/J1587 link. Howev-
er, instrument and indicator lamps are completely
turned off.
If faults occur in both links, the engine starts to idle.
The only way to shut off the engine in this case is to
use the auxiliary stop (AUX-STOP) placed on the en-
gines left side.

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 infor-
mation for, among other things, the flashing code. The
VODIA diagnosis tool also uses the J1708/J1587 link
to communicate with the system.

6
 General information

DCU - Display Control Unit

DCU is a digital instrument panel that communicates
with the engine control module via the CAN link. DCU
has several functions, such as:
Engine control
Start, stop, speed control, pre-heating etc.
Monitoring
Engine speed, charge pressure, charge tempera-
ture, coolant temperature, oil pressure, oil temper-
ature, engine hours, battery voltage, instanta-
neous fuel consumption and fuel consumption
(trip fuel).
Diagnostics
Shows fault codes in text. Lists previous faults.
Parameter setting
Idling speed, alarm limit for oil temperature/cool-
ant temperature, droop.
Preheating for ignition.
Information
Information about hardware, software and engine
identification.

DU - Display Unit
The DU is an instrument panel which shows engine
working values graphically on an LCD screen. It con-
sists of an computerised unit for permanent installa-
tion in a control panel.
The display communicates via the CAN link. It is con-
nected to the CAN link between the engine control unit
and the CIU or DCU.
Monitoring
Engine speed, charge pressure, charge tempera-
ture, coolant temperature, oil pressure, oil temper-
ature, fuel pressure, engine hours, battery volt-
age, instantaneous fuel consumption and average
fuel consumption (trip fuel).
Diagnostics
Shows active fault codes in plain language.

7
General information

Fuel control Cylinder balancing

The engines fuel requirement is analyzed up to 100
times per second (depending on engine rpm). The en-
gines injection amount and injection timing is controlled
electronically via fuel valves on the unit injectors.
This means that the engine always receives the cor-
rect volume of fuel in all operating conditions, which
offers lower fuel consumption, minimal exhaust emis-
sions etc.
The control unit checks and controls the unit injectors,
to ensure that the correct volume 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 past, through
the unit injectors holes and continuing out through the
fuel channel. Fuel is not sprayed into the cylinder in
this position.
When the fuel valve is closed, pressure is built up by
the mechanically driven pump piston in the unit injec-
tor. 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 injec-
tion 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.
When idling, the control module can supply the cylin-
der with different amounts of fuel. This is to give the
engine more even idling. At higher rpm, this problem
does not exist, and the cylinders receive the same
amount of fuel.
Altitude correction
The control unit contains an atmospheric pressure
sensor and an altitude compensation function for en-
gines that operate at high altitude. 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 overspeeding.
Diagnostic function
The task of the diagnostic function is to discover and
localize any malfunctions in the EMS 2 system, to
protect the engine and to inform about any problems
that occur.
If a malfunction is discovered, this is announced by
warning lamps, a flashing diagnostic lamp or in plain lan-
guage on the instrument panel, depending on the equip-
ment used. If a fault code is obtained as a flashing code
or in plain language, this is used for guidance in any fault
tracing. Fault codes can also be read by Volvos VODIA
tool at authorized Volvo Penta workshops.
In case of serious disturbances, the engine is shut
down completely or the control module decreases the
power output (depending on the application). Once
again, a fault code is set for guidance in any fault
tracing.

Calculation of fuel quantity

The quantity of fuel to be injected into the cylinder is
calculated by the control unit. The calculation deter-
mines the time that the fuel valve is closed (when the
fuel valve is closed fuel is sprayed into the cylinder).
The parameters which govern the amount of fuel in-
jected are:
Demanded engine speed
Engine protector functions
Temperature
Charge air pressure

8
 General information

Component location
NOTE! Location can differ, depending on engine model.
4 5
3
6

1 7

1. Speed sensor, camshaft

2. Connection, EMS 2
3. Solenoid controlled proportional valve, high pres-
sure pump fuel (MPROP)
4. Fuel pressure
5. Fuel pressure in distribution manifold
6. Spark plugs, one for each injector
7. Oil pressure sensor
8. Charge air pressure and temperature
9. Solenoid valve, EGR
10. Coolant temperature
8
11. Speed sensor, flywheel
12. Water in fuel (not shown, mounted on primary
fuel filter).

10
11

9
General information

Voltage feed 24 V
The positive and negative cables from the battery must
be connected to the starter motor terminals.
The positive cable from the battery must be connected Battery cable area
via a main switch to terminal 30 on the starter motor.
The total length (L) of the positive and negative ca-
The negative cable from the battery must be connect-
bles determines the cable area (A).
ed directly terminal 31 on the starter motor.
Note! Because of the fire risk, the total cable area
must not be less than 70 mm2
Battery specification
Max. battery 2x220 Ah (series connected).

Battery charging
Standard practice on all engines is that the batteries
are provided with power from the alternator.

Max L (m) 4 5 6,5

2
Min A (mm ) 70 95 120

Max 2 x 220 Ah (series connected)

10
 1. Oil level/temperature sensor
2. Oil pressure sensor
3. Fuel pressure sensor
4. Coolant temperature sensor
5. Fuel pressure supply
6. Oil pressure supply
7. Coolant temperature ground
8. Oil pressure ground
9. Fuel pressure ground
10. Coolant level sensor
11. Start relay
12. Internal EGR
13. Preheating sensor
14. Preheat relay
15. Preheating
16. Start relay
17. Internal EGR

P
Electrical diagram EMS2

18. Extra stop (AUX stop)

r
19. J1939 CAN (bus)
20. Battery negative

e
21. Battery plus
22. Voltage after key
23. Stop
24. J1587 (bus)

il m
25. Connector engine interface
26. Main relay
27. Main fuse 10 A

in
28. Battery (24 V)
29. MPROP

a
30. Unit injector (Cyl. 1-6)
31. Flywheel sensor
32. Camshaft sensor
33. Boost pressure
34. Boost temperature
35. Rail pressure
r y Cable colors
BL = Blue
36. Rail pressure supply LBL = Light blue
37. Boost pressure/tempersture BN = Brown
supply LBN = Light brown
38. Rail pressure ground GN = Green
39. Boost pressure/temperature GR = Gray
ground OR = Orange
40. Connector B P = Pink
41. Connector A R = Red
SB = Black
VO = Violet
W = White
Y = Yellow

Cable area = 0.75

mm2 unless other-
wise specified.

11
General information
General information

Cable colors
Wiring diagram CIU 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

Cable area = 0.75 mm2 unless

otherwise specified.

1. Key switch (15+) 16. Alarm, low coolant level

2. RPM potentiometer 17. Fuel alarm
3. Tachometer (code 14) 18. Diagnostic lamp
4. Oil pressure, instrument 19. Engine overspeed indication (GE)
5. Oil temperature, instrument Horn (VE)
6. Coolant temperature, instrument 20. Operation indicator
7. Instrument illumination 21. Pre-heating indication
8. Idling contact, two-way 22. Pre-heating contact
9. 1500 / 1800 rpm switch, two-way 23. 8-pin connector engine interface
10. Starter contact, spring biased 24. Governor switch
11. Stop switch, spring biased 25. Battery voltage alarm
12. Diagnosis contact, spring return 26. Termination resistance 120 Ohm
13. Alarm, low oil pressure 27. 8-pin connector engine interface
14. Alarm, high oil temperature 28. Contact, engine protector disconnect
15. Alarm, high coolant temperature 29. Easy Link connector block
30. Control Interface Unit (CIU)

12
 General information

Wiring diagram DCU

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

Cable area = 0.75 mm 2 unless

otherwise specified.

1. Start contact
2. Stop contact
3. 1-pin connector
4. Horn, buzzer alarm
5. Easy Link connector
6. RPM-potentiometer
7. Indicator engine operation
8. 8-pin connector engine interface
9. 8-pin connector engine interface
10. Termination resistance 120 Ohm
11. Display Control unit (DCU)

13
Control unit

Installing the control unit

Mechanical installation
NOTE! The control unit is equipped with an internal
atmospheric sensor (1) and must not be installed in-
side a pressurized area. Make sure that the holes for
the pressure sensor are not covered over.

The control unit is fixed by four M8 screws, which

should be torqued to 24 4 Nm.

Permissible angles:
30 from the horizontal axis
-5 A 185 (see figure 1)
-90 B 30 (see figure 2)
Fig. 1
0 C 5 (see figure 3)

Fig. 2

Fig. 3

14
 Control unit
The control unit has two, individually coded 62-pin
1 connectors, which are locked by a catch on each con-
nector. The cables are fixed at two points (1) by M8
screws, which should be torqued to 24 4 Nm.
The control unit is provided with vibration damping, to
protect it from vibration. Please refer to Vibration.
Each installation must be tested to verify that the vi-
bration requirements are complied with.
NOTE! Control units must be shielded from chemi-
cals.
NOTE! It is not permissible to install further compo-
nents on the control unit or its fixings.

Temperature
Min ambient temperature: .................................. - 40
Max ambient temperature: ................................. 90C

The installation temperature must be verified by mea-

suring the temperature inside the control unit in the
gray marked field (1), please refer to the figure.

15
Control unit

Vibration
Vibration levels are specified for the installation
points, so the unit has been equipped with vibration
damping.
The following levels must not be exceeded:
Frequency range ................................... 10-2000 Hz
Level
10-300 Hz ............................................................ 5 g
300-1000 Hz ......................................................... 10g
1000 Hz ............................................................... 25g
2000 Hz ................................................................ 5g

The vibration levels must not exceed the limits shown

in the figure. The measurements must be made on the
screws at the anchorage points, not the EMS unit
housing. The results of the measurements shall be re-
ported in the same units as on the axes of the graph.

Classification
The EMS is classified to IP 59K

16
 Control unit

Electrical installation

Max operating voltage ......................................... 36V

Nominal operating voltage ................................ 28.5V
The voltage must be 9 V higher for a period of 50 ms
immediately earlier.
The EMS unit has been certified in accordance with
the EMC directive for vehicles, please refer to 95/54
EC. The values therein must not be exceeded.
The EMS unit is supplied with current from a main
relay.
Joints in the cable for checking the solenoids or
to share sensors with other units.
The voltage drop between the battery and the EMS
unit supply terminals must not exceed 0.5 V.
The battery positive (+) side must have a 10 A fuse.

Recommended cable length and cable area:

NOTE! Cables longer than 10 m should be avoided.

Cable length Min cable area

0-5 m 1,5 mm2
5-10 2.5 mm2

Voltage drop between signal earth (ground) for the ECU

and battery earth (ground) must not exceed 0.5 V.

Earth (ground) cable

There is an earth (ground) cable on one of the ECU
units vibration dampers. This earth (ground) cable
must have good electric contact to comply with the
EMC Directive. The contact area must not be painted.
NOTE! The earth (ground) cable must be in tension
when the EMS unit is fixed. The earth (ground) cable
must not touch surrounding surfaces.

17
Control unit

Cables and connectors

The area round the connectors must be 118 mm high
and there must be enough space all round so that the
connectors can be connected/separated.
The cables must be angled when installed, to avoid
water entry. Please refer to the figure.
The first fixing point for the cables must be on the
control unit, to avoid movement between the control
unit and the cables.
No installation of extra cables on the control unit is
permissible. This is because of the vibration.

18
CIU

CIU

General
The installation must be planned very thoroughly and Avoid making joints in the system as far as possible.
done with the greatest care. Cables and any joints must be accessible for inspec-
Secure the connecting cable between motor and in- tion and service.
strument panel with clamps. Remember that the strain NOTE! The connectors must be installed dry, they
on the connectors must be relieved so that they are must not be packed with Vaseline etc.
not subjected to any pull.
Cables must not be run too close to hot components
on the engine or close to any other source of heat.
Make sure that it is protected from mechanical wear,
sharp edges and water splashes. If necessary, run the
cable through protective conduits.

19
 CIU

Connection, CIU
Engine control
(please refer to Wiring diagram CIU)
R NO = Normally open

STOP
NC = Normally closed
SWITCH

VO
Starter switch
R/BL 1.5
ON The ignition lock is used for connection of system
SWITCH
voltage, pre-heating function, start function and stop
R 2.5 function.
R/Y Position 0 = engine shut off
START
SWITCH Position I = system voltage switched on
R Position II = pre-heating on (spring biased)
Position III = starter motor engaged (spring biased)
OR
PRE HEAT
Position S = stop function on (spring biased)
SWITCH

NOTE! The starting current for engine system voltage

(control unit) is 10 A. Make sure that other compo-
S nents in the installation are dimensioned for this cur-
rent density.

S 15A15B 30 50 19
BL/GN
Pre-heat
R/Y
Start
R 1.5
Batt +
R/BL
15 key switch
VO
Stop

20
CIU

Governor switch
Contact type, two-position. Selects which governor to
0.5-2 k 2-10 k 0.5-2 k
use, isochronous or droop.

idle full Accelerator

throttle
Idling: 0.3-1.9 V (preset value 1.17 V)
Full throttle: 1.9-4.7 V (preset value 4.5 V)
optional max 2 k

If an accelerator pedal with different resistance and

voltage values is used, the control unit must be re-cal-
POT POT SIG- POT +
NAL
ibrated with the parameter tool, please refer to Pa-
rameter setting.

GN/Y GN/
OR Idle contact
SPEED
The accelerator has a built-in idling switch, which
CONTROL functions as a Limp home device if the potentiome-
R/GR ter in the accelerator pedal fails.
IDLE SPEED
SWITCH
When the pedal is depressed, the contact is closed
and the engine progressively accelerates to 80% of
full speed.
R/BL When the pedal is released, the contact is opened and
GN/SB engine speed falls to idling at once.

Warning and indication lamps

The warning and indication lamps listed below are
available. Specs for all lamps:
Max. power 3 W
Voltage 24 V
(please refer to Wiring diagram CIU)
Alarm, low oil pressure
Alarm, high oil temperature
Alarm, high coolant temperature
Alarm, low coolant level
Fuel alarm
Charge indication
Diagnostic lamp
Pre-heating indication

21
 CIU

Instruments
(please refer to Wiring diagram CIU)

Tachometer
R/BL Use Volvo Penta universal tachometer, graduated
02600 rpm.

SB
Set code 14, see installation instructions 7739513-5.

TACHO

R/SB

GR/SB

Oil pressure instrument

Use Volvo Penta oil pressure instrument, graduated
010 bar.
LBL

R/SB

OIL PRESS.

SB

R/BL

Oil temperature instrument

R/SB

OIL TEMP

SB
R/BL

22
Diagnostic function

Use Volvo Penta oil temperature instrument, graduat-

ed 40150C.
Coolant temperature instrument
LBN

R/SB

COOLANT TEMP
INSTRUMENT

SB

R/BL

Use Volvo Penta coolant temperature instrument,

graduated 40120C.
Easy Link
For parallel connection of up to 20 extra VDO-instru-
ments. The instruments automatically find their re-
spective parameter group in the data bus.
The following instruments are available:
- Engine speed / hours counter (fault codes are
also displayed on the tachometer display when
the diagnostic button is pressed)
- Coolant temperature
- Oil pressure
- Oil temperature
- Battery voltage
- Alarm panel
- Turbo pressure

Other
(please refer to Wiring diagram CIU)

Diagnostic connector
Contact type, closing (NO), spring biased.
For reading of fault codes, see chap. Fault tracing.

Contact, engine protector disconnect

Contact type, closing (NO), spring biased.
A brief press gives disconnection for 10 seconds.
If the spring is depressed for longer, the engine pro-
tection is disconnected for up to 60 seconds.

23
 DCU

DCU

General
The installation must be planned very thoroughly and Avoid making joints in the system as far as possible.
done with the greatest care. Cables and any joints must be accessible for inspec-
Secure the connecting cable between motor and in- tion and service.
strument panel with clamps. Remember that the strain NOTE! The connectors must be installed dry, they
on the connectors must be relieved so that they are must not be packed with Vaseline etc.
not subjected to any pull.
Cables must not be run too close to hot components
on the engine or close to any other source of heat.
Make sure that it is protected from mechanical wear,
sharp edges and water splashes. If necessary, run the
cable through protective conduits.

24
DCU

Connection, DCU

Display Control unit (DCU) RPM potentiometer

The DCU is connected via the 8-pin data bus connec- Max. potentiometer value: 0-10 V (preset value 9 V)
tor. Please refer to Component location, page 8.
Min. potentiometer value 0-10 V (preset value 1 V)
The signal can be inverted, please refer to the dia-
Start contact gram below.
Contact type, closing (NO), spring biased.
Potentiometer
value (%)
Stop contact
Contact type, closing (NO), spring biased.
100

Easy Link
For parallel connection of up to 20 extra VDO-instru-
ments. The instruments automatically find their re-
spective parameter group in the data bus. The maxi- 0
mum length of the Easy Link cables is 3m. Voltage (V)
1 9
The following instruments are available:
- Tachometer/ Operation hours
Potentiometer
- Coolant temperature value (%)
- Oil pressure
- Oil temp 100
- Battery voltage
- Charge pressure
- Alarm panel

0
Voltage (V)
Warning and indication lamps 1 9

Indicator, engine operation

Max. power ........................................................ 3 W
Voltage ............................................................. 24 V

25
 Parameter settings

Parameter settings
Connection, VODIA parameter tool

Operation, VODIA
Using the VODIA-tool (3838619), in Parameters, re-
programming mode, you can read and adjust the pa-
rameters listed below. The VODIA tool is connected
to the diagnostic connector (6-pin connector) found
under the cable cover on the left of the engine or by
using the diagnostic connector T-piece no. 874427.
Please refer to the VODIA Users Guide for advice
on use.

26
Parameter settings

Adjustable parameters,
NOTE! The parameters in the CIU and EMS2 are ad-
justed via VODIA. Some parameters require special
authorization.

Functions
Primary control position
Selects which governor to use when no governor Connected to system voltage during
switch is used. Operation/Stop, CIU
Alternative position .............. Isochronous or Droop Stop input on CIU unit connected to system voltage at
Preset position ..................................... Isochronous Run or Stop.
Preset position ................................................. Stop
Control gradient
Selects how much speed drop to use (gradient) Idle voltage, CIU
Min. value ................................................ 10 Nm/rpm Voltage at accelerator input on the CIU-unit that corre-
Preset value ............................................. 25 Nm/rpm sponds to idle.
Max. value ............................................. 127 Nm/rpm
Min. value ......................................................... 0.3 V
Preset value .................................................... 1.17 V
Lamp test Max. value ........................................................ 1.9 V
This parameter selects whether lamp test shall be per-
formed when the system is started. Max. speed voltage, CIU
Alternative position ............................... Off or On Voltage at accelerator input on the CIU-unit that corre-
Preset position .................................................. On sponds to full throttle.
Min. value ......................................................... 1.9 V
Idling speed. Preset value ...................................................... 4.5 V
Max. value ........................................................ 4.7 V
Setting idling speed.
Min. value 550 rpm
Preset value 600 rpm
Max. value 800 rpm

Pre-heating for ignition
Selects whether pre-heating should be activated di-
rectly when ignition is turned on. If the On parameter
has been set to the Off position, pre-heating must be
activated manually via the ignition key or pre-heating
knob.
Alternative position ............................... Off or On
Preset position ................................................... Off
Alarm limits
Alarm limit for coolant temperature
at this temperature, a warning lamp turns on.
Min. value .......................................................... 95C
Preset value ....................................................... 98C
Max. value ....................................................... 101C

Connected to system voltage during

Operation/Stop, EMS
Stop input on CIU unit connected to system voltage at
Run or Stop.
Preset position ................................................. Stop

27
Parameter settings

Engine protector

Engine protector coolant Engine protection, charge air

temperature
Chooses whether engine protection should be activat-
ed in relation to high coolant temperature.
A fault code is set and the engine is shut down.
Alternative positions .............................. Off or On
Default value ..................................................... On
pressure
Selects whether engine protector should be activated,
with regard to high charge air pressure.
A fault code is set and the engine is shut down.
Alternative positions ............................... Off or On
Default value ...................................................... On

Engine protector coolant level Engine protector oil pressure

Chooses whether engine protection should be activat-
ed in relation to low coolant level.
A fault code is set and the engine is shut down.
Alternative positions ............................... Off or On
Default value ..................................................... On
Chooses whether engine protection should be activat-
ed in relation to low oil pressure.
A fault code is set and the engine is shut down.
Alternative positions .............................. Off or On
Default value ..................................................... On

Engine protector charge air

temperature
Selects whether engine protector should be activated,
with regard to high charge air temperature.
A fault code is set and the engine is shut down.
Alternative positions .............................. Off or On
Default value ..................................................... On

28
Fault tracing

Fault tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below. Always con-
tact your Volvo Penta dealer if any problems occur which you can not solve by yourself.

WARNING! Read through the safety advice for care and maintenance work in the chapter entitled Safety-
information before you start work.

Symptoms and possible causes

The diagnosis button lamp flashes Please refer to the Diagnostic information chapter
Engine can not be stopped 2, 5
Starter motor does not rotate 1, 2, 3, 4, 5, 6, 7, 24
Starter motor rotates slowly 1, 2
Starter motor rotates normally but engine does not start 8, 9, 10, 11,
Engine starts but stops again 8, 9, 10, 11, 13
Engine does not reach correct operating speed at full throttle 9, 10, 11, 12, 13, 21, 25, 26
Engine runs roughly 10, 11
High fuel consumption 12, 13, 15, 25
Black exhaust smoke 12, 13
Blue or white exhaust smoke 15, 22
Too low lubrication oil pressure 16
Excessive coolant temperature 17, 18, 19, 20
Too low coolant temperature 20
No, or poor charge 2, 23

1. Flat batteries 11. Water/contamination in fuel 21. Blocked intercooler

2. Poor contact/open circuit in ca- 12. Faulty unit injector 22. Too high oil level
bles 13. Insufficient air supply to 23. Alternator drive belt slips
3. Main switch turned off engine: 24. Water entry into engine
4. Main circuit breaker faulty blocked air filter
air leakage between turbo 25. High back pressure in exhaust
5. Faulty ignition lock and inlet manifold system
6. Faulty main relay fouled compressor section in 26. Break in Pot+ cable to pedal
the turbocharger
7. Faulty starter motor/solenoid
faulty turbocharger
8. Lack of fuel: poor engine bay ventilation
fuel taps closed
14. Excessive coolant temperature
fuel tank empty/wrong tank
connected 15. Too low coolant temperature
9. Blocked secondary fuel filter/ 16. Too low oil level
primary filter (because of con- 17. Coolant level too low
tamination, or stratification in
the fuel at low 18. Air in the coolant system

10. Air in the fuel system 19. Faulty circulation pump

20. Defective thermostat

29
 Diagnostic function

Diagnostic function
The diagnostic function monitors and checks that the EMS 2 system functions normally.
The diagnostic function has the following tasks:
Discover and localize malfunctions
Notify that malfunctions have been discovered
Give advice in fault finding

Fault code
If the diagnostic function discovers a malfunction in
the EMS-2 system, this is reported by means of fault
codes/fault messages on the instruments.
Both active (un-mended) and passive (mended) faults
are stored in the control unit.
Please 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, reac-
tion and measures to be taken. Please refer to the
Fault codes chapter.
NOTE! All instruments are optional
Active faults
DCU (Display Control Unit)
text !! ENGINE WARNING !! is shown on the
display.
NOTE! You can choose the language that the informa-
tion is presented in.
CIU (Control Interface Unit)
the diagnostic lamp starts to flash.
Easy Link instrument (only with CIU)
- 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.
NOTE! You can choose the language that the informa-
tion is presented in.
Fault codes can also be read by means of the
VODIA tool. Please refer to the VODIA Users
Guide for advice on use.
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 disap-
pears as active.
Inactive faults
DCU - the fault is indicated as passive
CIU - the diagnostic lamp goes out
DU - the fault message disappears (inactive faults
can not be read out)
Easy Link - the lamp on the alarm panel goes out
Effect on engine
Engines are affected differently, depending on the se-
verity 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 di-
agnostic function.
Engines are affected differently, depending on the se-
verity of the fault.
The engine is not affected
Engine idles
Engine torque is restricted to a certain amount
Engine is stopped

30
Diagnostic function

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 codes.
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 that has been set 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 that has been set, by observing the flashing
of the diagnostic lamp. Please 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 following
text will appear on the display: WARNING! or
ALARM STOP (a buzzer sounds).
1. Press any button to come to the fault list.
The fault list shows:
- Operation hours
- Fault message
2. Look up the fault code in the Fault Code chapter
and take the recommended measures.
3. Press ACK to confirm the fault code. The display
background will change color (the buzzer stops
sounding).

3. Look up the fault code in the Fault Code chapter 4. Press EXIT to leave the fault list.
and take the recommended measures.

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 with
Press SEL for information.
NOTE! You can choose the language that the informa-
tion is presented in.
Read the fault code as follows:
1. Press the 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 the Fault Code chapter
and take the recommended measures.
3. Press the ESC button to leave the fault list.
NOTE! To enter the fault list when no fault code has
been set, press the SEL button and select Diagnos-
tics from the menu.

31
Diagnostic function

Reading fault codes via the diagnostic Reading the fault codes via an Easy
lamp on the instrument panel, CIU link instrument (only with a CIU)
When the system has discovered a malfunction, the When the system has discovered a malfunction, this
diagnostic lamp starts to flash. If the diagnostic button is reported by the diagnostic lamp which starts to
is depressed and then released, a fault code is flashed flash.
out.
1. Press the diagnostic button. The fault code is
The fault code consists of two groups of flashes, sep-
shown as text on the tachometer display.
arated by a pause of two seconds. A fault code is ob-
tained by counting the number of flashes in each 2. Look up the fault code in the Fault Code chapter
group. and take the recommended measures.
Example: pause = Fault code 2.4 3. When the fault has been rectified, the fault code
disappears from the display and the diagnostic
The fault code is stored and can be read as long as
lamp goes out.
the malfunction remains. You can find information
about cause, reaction and actions in the Fault Code
chapter.
Read the fault code as follows:
1. Press the diagnostic button.
2. Release the diagnostic button and make a note of
the fault that is flashed out. Erasing fault codes
3. Repeat items 1-2. A new fault code is flashed out Fault codes must be erased by means of the VODIA
if more are stored. Repeat until the first fault code tool.
is repeated.
NOTE! When the first fault code is repeated, all fault
codes have been read out.
If the diagnostic button is pressed after the fault has
been mended and the fault codes have been erased,
code 1.1 No fault will be displayed.

32
 Fault codes

Fault codes
WARNING! Read through the safety advice for care and maintenance work in the Safety information chap-
ter before you start work.

NOTE! Reading the fault codes below, such as Code 2.1, PID 97 means that 2.1 is the flashing code indicated by
the diagnostic lamp. PID 97 is read with the VODIA diagnostic tool. With the use of DCU or DU the fault mes-
sage will be shown as text in the display.

NOTE! Please refer to Wiring schedule CIU and DCU for references to the sleeves in the electrical connectors
on the engine control unit.

Code 1.1 No faults Code 2.3, PID / SPN 111. Coolant level sensor
There are no active faults. Cause:

Short circuit to positive (+).

Code 2.1, PID / SPN 97, Water in fuel Fault in sensor.
Cause: Reaction:

Water in fuel. None.

Reaction: Remedy:

None. Check that the coolant level sensor cable is not

damaged.
Remedy:
Check coolant level sensor function.
Empty the primary fuel filter.
Code 2.4, SID21 / SPN 637
Code 2.2, PID / SPN 111. Coolant level Flywheel speed sensor
Cause: Cause:

Low coolant level. No signal.

Reaction: Abnormal frequency.
Warning indication. Intermittent signal from the sensor.
Engine control module reduces engine power (un- Fault in sensor.
less the protection has been shut off with the
VODIA diagnostic tool). Reaction:

Remedy: Engine is very difficult to start and runs roughly

Check the coolant level.
Check coolant level monitor function.
when it starts.
Remedy:
Check that the sensor connector is correctly in-
stalled.
Check that the engine speed sensor cable is not
damaged.
Check that the engine speed sensor is correctly
installed in the flywheelhousing.
Check engine speed sensor function.

33
Fault codes

Code 2.5, SID22 / SPN 636

Code 2.9, PID / SPN 97, Indicator for water in fuel
Camshaft drive speed sensor
Cause:
Cause:
Short circuit
No signal.
Open circuit.
Abnormal frequency.
Fault in indicator.
Fault in sensor.
Reaction:
Reaction:
None.
Engine takes longer to start than normal. Engine
runs normally when running. Remedy:
Remedy: Check the indicator cables for breaks and short
Check that the engine speed sensor connector is circuits.

correctly installed.
Check that the engine speed sensor cable is not
damaged.
Check that the engine speed sensor is correctly
Check indicator function. Change indicator as nec-
essary
Code 3.1, PID / SPN 100, Oil pressure sensor

installed in the upper timing gear cover. Cause:

Check engine speed sensor function. Short circuit to positive (+) or earth (ground) ().
Code 2.6, PID / SPN 190, Code 2.6 Engine speed Open circuit.
Cause: Reaction:
Engine speed too high. None.
Reaction: Remedy:
None. Check that the oil pressure sensor cable is not
Remedy: damaged.
Check that the oil pressure sensor is correctly
After the engine has stopped, look for the reason connected.
for the high speed.
Code 3.2, PID / SPN 105
Code 2.8, PPID 132 / SPN 608, Charge air temperature sensor
Speed potentiometer connected to CIU
Cause:
Cause:
Short circuit to positive (+) or earth (ground) ().
Shorted to plus (+) or minus (-).
Open circuit.
Fault in sensor.
Reaction:
Reaction:
None.
Engine goes to idle.
Remedy:
If you release the accelerator first, and the press Check that the charge air temperature sensor con-
it down again, the engine can be forced to run us- nector is correctly installed.
ing the idle contact.
Check that the charge air temperature sensor ca-
Remedy: ble is not damaged.

Check that the potentiometer has been connected
correctly.
Check that the cable harness to the potentiometer
has not been damaged.
Check that the charge air temperature sensor is
correctly installed.
Check charge air temperature sensor function.

Check the potentiometer function.

34
 Fault codes

Code 3.3, PID / SPN 110

Code 3.6, PID / SPN 94, Fuel pressure sensor
Coolant temperature sensor
Cause:
Cause:
Short circuit to positive (+) or earth (ground) ().
Short circuit to positive (+) or earth (ground) ().
Open circuit.
Open circuit.
Reaction:
Reaction:
None.
Preheating is also activated when the engine is hot.
Remedy:
Remedy:
Check that the fuel pressure sensor connector is
Check that the coolant temperature sensor con-
correctly installed.
nector is correctly installed.
Check that the fuel pressure sensor cable is not
Check that the coolant temperature sensor cable
damaged.
is not damaged.
Check that the fuel pressure sensor is correctly
Check that the coolant temperature sensor is cor-
installed.
rectly installed.
Check fuel pressure sensor function.
Check coolant temperature sensor function.
Code 3.7, PID / SPN 175, Oil temperature sensor
Code 3.4, PID / SPN 106/102,
Charge pressure sensor Cause:

Cause: Shorted to plus (+) or minus (-).

Short circuit to positive (+) or earth (ground) (). Break.

Reaction:
Open circuit.
Reaction: None.
Remedy:
Engine smokes more than normally during accel-
eration/load increase. Check that the cable harness to the oil tempera-
ture sensor has not been damaged.
Remedy:
Check that the oil temperature sensor has been
Check that the charge pressure sensor connector connected correctly.
is correctly installed.
Check that the charge pressure sensor cable is Code 3.8, PID / SPN 94, Fuel pressure
not damaged. Cause:
Check that the charge pressure sensor is correct-
Low supply pressure.
ly installed.
Check charge pressure sensor function. Reaction:

None.
Code 3.5, PID / SPN 106/102, Charge pressure
Remedy:
Cause:
Check if it is possible to build up pressure with
Charge pressure too high the hand pump.
Reaction: Check the fuel filter.
Engine control module reduces engine power (un- Check the fuel pre-filter.
less the protection has been shut off with the
VODIA diagnostic tool).

Remedy:

Check turbocharger compressor function.

Check charge pressure sensor function.

Check fuel volume/injector.

35
Fault codes

Code 3.9, PID / SPN 158, Battery voltage, EMS Code 5.3, PPID 6/ SPN 970, Stop input CIU
Cause: Cause:

Faulty alternator. Short circuit to negative (-).

Faulty battery, battery cables. Open circuit.

Reaction: Activated for too long time.
None. Reaction:
Remedy: Engine can only be stopped with the auxiliary stop
Check the supply voltage from the control unit. (AUX STOP) on engine.

Engine stops. A fault code is displayed for 40

Code 4.8, PPID 6/ SPN 520195, Stop input EMS seconds and the engine can not be started during
Cause: this time. When a fault code is active, the engine
can be started but not stopped.
Short circuit to negative (-).
Remedy:
Open circuit.
Check that the starter switch connections are not
Reaction: damaged.
Engine can only be stopped with the auxiliary Check that the ignition switch cable is not
stop. damaged.

Remedy: Code 5.4, PID 45/ SPN 626, Preheating relay

Check that the starter switch connections are not Cause:
damaged.
Short circuit to positive (+) or earth (ground) ().
Code 5.2, PPID 4 / SPN 520194, Starter input CIU
Open circuit.
Cause:
Reaction:
Shorted to minus (-).
Preheating can not be activated.
Activated for too long.
Preheating is constantly connected.
Reaction:
Remedy:
The engine cannot be started.
Check that the relay input cable is not damaged.
The engine starts immediately when ignition is tur- Check relay function.
ned on.
Code 5.7, PID / SPN 98, Oil level
Remedy:
Cause:
Check that connections to the ignition key have
not been damaged. Oil level is too low.
Check that the cable harness to the ignition key Reaction:
has not been damaged.
Warning indication.
Remedy:

Check the oil level.

36
 Fault codes

Code 5.8, PID / SPN 175, Oil temperature Code 6.2, PID / SPN 105, Charge air temperature
Cause: Cause:

Oil temperature is too high Charge air temperature is too high.

Reaction: Reaction:

Warning indication. Engine control module reduces engine power (un-

less the protection has been shut off with the
The engine control module limits engine output VODIA diagnostic tool).
(unless protection has been turned off with the
diagnosis tool VODIA). Remedy:

Remedy: Check the coolant level.

Check the intercooler (cleanliness).
Check the oil level.
Check charge air temperature sensor function.
Check the oil temperature. Check the function of the thermostat.
Check the oil temperature sensor function.
Code 6.3, PPID 3 / SID 39 / SPN 677
Start output EMS / SID 39 / SPN Start motor relay
Code 5.9, PID / SPN 98, Oil level sensor
Cause: Cause:

Shorted to plus (+) or minus (-). Shorted to plus (+) or minus (-).
Break. Activated for too long.
Reaction: Reaction:

None. The engine cannot be started.

Remedy: The engine starts immediately when ignition is tur-
Check that the cable harness to the oil level sen- ned on.
sor has not been damaged. Remedy:

Check the oil level sensor function. Check that connections to the ignition key have
not been damaged.
Code 6.1, PID / SPN 110, Coolant temperature Check that the cable harness to the ignition key

Cause: has not been damaged.

Coolant temperature is too high.
Reaction:
Engine control module reduces engine power (un-
less the protection has been shut off with the
VODIA diagnostic tool).
Remedy:
Check the coolant level.
Check the intercooler (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.
Code 6.4, PPID 231 / SPN 639, Data link (CAN),
CIU
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.

37
Fault codes

Code 6.5, PPID 231 / SPN 639, Code 6.8, PPID 8 / SPN 520192,
Data link (CAN), EMS 2 Piston cooling pressure sensor
Cause: Cause:

Internal fault in control module. Shorted to plus (+) or minus (-).

Reaction: Break.
Engine not operating: engine can not be started. Reaction:
Engine operating: engine idles and can only be
stopped with the auxiliary stop (AUX-stop). None.

Remedy: Remedy:

Check that the 8-pin connector is not damaged. Check that the piston cooling pressure sensor
contact is correctly installed.
Check that the cables between the CIU and the
engine management unit are not damaged. Check that the cable harness to the piston cooling
pressure sensor has not been damaged.
Check that sleeves 11 and 12 in the connector on
the CIU are not damaged. Check the piston cooling pressure sensor func-
tionality.
Code 6.6, PID / SPN 100, Oil pressure
Code 6.9, PID / SPN 158, Battery voltage, CIU
Cause:
Cause:
Oil pressure is too low.
Short circuit to negative (-).
Reaction:
Faulty alternator.
Engine control module reduces engine power (un-
less the protection has been shut off with the Faulty battery, battery cables.
VODIA diagnostic tool).
Reaction:
Remedy:
Problems in engine starting.
Check oil level.
Remedy:
Check that the air filters are not blocked.
Check system pressure valves and safety valves Check the supply voltage from the control unit.
in the oil system. Check the battery.
Check oil pressure sensor function.
Check the alternator.
Code 6.7, PPID 8 / SPN 520192,
Piston cooling pressure Check the 8-pin contact.

Cause:

Piston cooling pressure is too low.

Reaction:

Engine stopped. The fault code is de-activated at

engine speeds below 1000 rpm.
Remedy:

Check that the oil pressure in the engine exceeds

175 kPa (25.4 psi).

38
 Fault codes

Code 7.1, SID 1 / SPN 651, Code 7.3, SID 3 / SPN 653
Injector, cylinder #1 Injector, cylinder #3
Cause: Cause:

Electrical fault. Electrical fault.

Faulty compression or injector. Faulty compression or injector.

Reaction: Reaction:

Engine runs on 5 cylinders. Engine runs on 5 cylinders.

Abnormal sound. Abnormal sound.

Reduced performance. Reduced performance.

Remedy:
Check that the injector cables are not damaged.
Check that the injector connections are not dam-
aged.
Check fuel supply pressure.
Check the valve clearance.
Do a compression test and check cylinder #1.
Code 7.2, SID 2 / SPN 652,
Injector, cylinder #2
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 dam-
aged.
Check fuel supply pressure.
Check the valve clearance.
Do a compression test and check cylinder #2.
Remedy:
Check that the injector cables are not damaged.
Check that the injector connections are not dam-
aged.
Check fuel supply pressure.
Check the valve clearance.
Do a compression test and check cylinder #3.
Code 7.4, SID 4 / SPN 654
Injector, cylinder #4
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 dam-
aged.
Check fuel supply pressure.
Check the valve clearance.
Do a compression test and check cylinder #4.

39
Fault codes

Code 7.5, SID 5 / SPN 655 Code 7.7, PID / SPN 153
Injector, cylinder #5 Crankcase ventilation pressure
Cause: Cause:

Electrical fault. Crankcase ventilation pressure too high.

Faulty compression or injector. Reaction:

Reaction: The engine is shut down (if the protection has not
been shut off by the parameter tool).
Engine runs on 5 cylinders.
Remedy:
Abnormal sound.
Check whether the crankcase ventilation is bloc-
Reduced performance. ked.
Remedy: Check whether cylinder liner, piston or piston rings
Check that the injector cables are not damaged. are worn or damaged.
Check that the injector connections are not dam- Code 7.8, PID / SPN 153,
aged. Crankcase ventilation pressure sensor
Check fuel supply pressure.
Cause:
Check the valve clearance.
Shorted to plus (+) or minus (-).
Do a compression test and check cylinder #5.
Code 7.6, SID 6 / SPN 656 Break.
Injector, cylinder #6
Reaction:
Cause:
None.
Electrical fault.
Remedy:
Faulty compression or injector. Check that the crankcase ventilation pressure

Reaction: sensor contact is correctly installed.
Check that the cable harness to the crankcase
Engine runs on 5 cylinders.
ventilation pressure sensor has not been dam-
Abnormal sound. aged.
Check crankcase ventilation pressure sensor
Reduced performance.
function.
Remedy:
Code 7.9, PID / SPN 172,
Check that the injector cables are not damaged.
Air temperature sensor, inlet
Check that the injector connections are not dam-
Cause:
aged.
Check fuel supply pressure. Shorted to plus (+) or minus (-).
Check the valve clearance. Break.
Do a compression test and check cylinder #6. Reaction:

None.
Remedy:

Check that the air temperature sensor contact is

correctly installed.
Check that the cable harness to the air tempera-
ture sensor has not been damaged.
Check the air temperature sensor functionality.

40
 Fault codes

Code 9.2, SID250 / SPN 608 Code 9.8, PPID 254 / SPN 629
Faulty data link (J1587) Fault in control unit, CIU
Cause: Cause:

Faulty data link. Faulty EEPROM, CIU.

Reaction: Faulty flash memory, CIU.
None. Fault in control module, CIU
Remedy: Reaction:
Check that the 8-pin connector is not damaged.
CIU returns to factory setting.
Check that the cables between the CIU/DCU and
the engine management unit are not damaged. Engine goes to idle.

Code 9.3, SID 232 / SPN 620 Engine can not be started.
Power supply to sensor Remedy:
Cause:
Re- program the unit
Shortcut.
Change CIU unit.
Fault in sensor.
Code 9.9, SID 240 / SPN 639, Memory fault
Reaction:
Cause:
Faulty values in oil pressure and charge air pres-
sure sensors. Memory fault in engine management system.
Reaction:
Fault code for oil pressure- and charge air pres-
sure sensor. Engine might not start.
Low engine output. Remedy:

The instrument shows zero oil pressure and boost Re-program the unit.
pressure.
Change engine control unit (EMS).
Remedy:
Code 9.9, SID 253 / SPN 630
Check that the cable harness to oil pressure and Data set memory EEPROM, EMS
charge air pressure sensor has not been dam-
aged. Cause:

Check oil pressure and charge air pressure sen- Internal fault in control module
sors.
Programming faulty.
Code 9.8, SID 253 / SPN 630 Reaction:
Data set memory EEPROM, CIU
Engine does not start.
Cause:
Remedy:
Internal fault in control module
Re-program the control module. If the fault re-
Programming faulty. mains, change the control module.
Reaction: Code 9.9, SID 254 / SPN 629
Control module EMS
Engine does not start.
Cause:
Remedy:
Internal fault in control module.
Re-program the control module. If the fault re-
mains, change the control module. Reaction:

Engine misfires.

Engine does not start.

Remedy:

Change engine control unit.

41
Fault codes

PID / SPN 164, Injection pressure PSID 96 / SPN 1239, Pressure in common rail
Cause: Cause:

Fault in fuel supply. Leakage in high pressure fuel system.

Fault in fuelpump. Leakage in high pressure pipes to injectors.

Fault in cable harness. Reaction:

Fault in sensor. Engine control module reduces engine power (un-

less the protection has been shut off with the
Reaktion: VODIA diagnostic tool).
Warning indication. Remedy:

Engine control module reduces engine power (un- Contact an autorized Volvo Penta workshop.
less the protection has been shut off with the
VODIA diagnostic tool). PSID 97 / SPN 679, Pressure valve
Remedy: Cause:

Check the cable harness. Leakage in PRV (Pressure Release Valve).

Check the sensor. PRV is stuck in closed position.

Check the filter. PRV is stuck in open position.

Reaction:
Check the fuelpumps.
Engine control module reduces engine power (un-
SID 42 / SPN 679, Injection pressure, regulator less the protection has been shut off with the
Cause: VODIA diagnostic tool).

Fault in cable harness. Remedy:

Fault in actuator. Contact an autorized Volvo Penta workshop.

Reaction: PPID 19 / SPN 2791, Internal EGR

Engine control module reduces engine power (un-
less the protection has been shut off with the
VODIA diagnostic tool).
Remedy:
Contact an autorized Volvo Penta workshop.
SID 70 / SPN 729, Preheating sensor
Cause:
Fault in cable harness.
Cause:
Fault in cable harness (boost pressure sensor).
Mechanical fault on the IEGR
Reaction:
Engine control module reduces engine power (un-
less the protection has been shut off with the
VODIA diagnostic tool).
Remedy:

Fault in preheating relay. Check cable harness (boost pressure sensor).

Reaktion:
Check the IEGR.
Preheating can not be activated.
Remedy:

Check the cable harness.

Check the preheating relay.

42
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 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: ............................................................................

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Refers to publication: .............................................................................................................................................

Publication no: ............................................................... Date of issue: .................................................................

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Name: ...............................................................

AB Volvo Penta
Teknisk Information
Avd. 42200
SE-405 08 Gteborg
Sweden
7745779 English 11-2005