VOLVO 7748542 - US - Installation EMS 2 - D13
VOLVO 7748542 - US - Installation EMS 2 - D13
EMS 2
Industrial Engines
I
1(1)
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
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.
p0005125
9812519 Multimeter
Multimeter
P0003813
HDT-4800
Press tool
P0003810
P0003811
P0003809
P0003811
P0003813
P0003814
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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.
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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.
Motor protector
Temperature
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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
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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
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Location of Sensors
2
8
4
7
5
6
9
14
10
13
12
11
P0004318
1. Extra stop
10
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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
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
Wiring Diagram
P0010912
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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.
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13
14
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
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.
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15
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
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17
Power supply
NOTICE! The engines are equipped with a 2-pole electrical system. This means that the positive and negative cables from the battery must be connected to the
starter motor terminals.
The positive cable from the battery may be run via a
main switch to terminal 30 on the starter motor.
The negative cable from the battery must be connected directly to terminal 31 on the starter motor.
Refer to the illustration below.
30
31
P0004300
18
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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.
(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).
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19
CIU
TAD1341GE, TAD1342GE, TAD1343GE,
TAD1344GE, TAD1345GE, TAD1350GE,
TAD1351GE, TAD1352GE, TAD1353GE
F
P0004306
20
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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
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21
22
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CIU
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE
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23
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.
P0003965
Stop contact
ON contact
Start lock
Pre-heating contact
P0003966
Pre-heating
Start
Batt +
15 start lock
Stop
24
A
B
C
D
E
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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
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25
DCU
C
A
P0005826
26
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27
Rpm-potentiometer
TAD1341GE, TAD1342GE, TAD1343GE,
TAD1344GE, TAD1345GE, TAD1350GE,
TAD1351GE, TAD1352GE, TAD1353GE
The values from the rpm potentiometer in-I or output
signal from the connection to an external load distribution system can be set in the DCU.
Nominal revolutions minus 120 rpm: 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
9V
Rpm-potentiometer
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE
It is possible to invert the signal; see the diagram
below.
P0005815
P0005816
28
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29
Instruments
Easy Link Instrument (option)
Refer to the System Information page 12 for the applicable engine.
For parallel connection of up to 20 extra VDO instruments.
The instruments will automatically find their own
parameter group from the databus. Maximum Easy
Link cable length is 3 m.
The following instruments are available:
Tachometer/operating hours
Coolant temperature
Oil pressure
P0005054
Oil temperature
Battery voltage
Retaining collar
Retaining bracket
P0005053
P0005052
P0005051
30
3-pin connector
3-pole connector
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P0003961
P0003961
P0003961
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31
32
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A
B
C
A
B
C
0.7 V
2.75 V
4.8 V
P0005829
P0003964
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33
Parameter Setting
Connection of special tool VODIA
Connection of special tool VODIA
P0001169
Function
It is possible to read and adjust parameters with the
VODIA tool, part no.3838619, as described in the following pages.
The VODIA tool is connected to the diagnostic outlet
6-pin connector located on the left side of the engine.
Refer to the VODIA user directions for instructions.
34
7748542 10-2009
Adjustable parameters
TAD1341GE, TAD1342GE, TAD1343GE,
TAD1344GE, TAD1345GE, TAD1350GE,
TAD1351GE, TAD1352GE, TAD1353GE
NOTICE! Some parameters require special authorization.
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
Stop function
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
Idling speed
Setting idle revolutions.
Min. value: 600 rpm
Max. value: 1200 rpm
Preset value: 900 rpm
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35
Adjustable parameters
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE
NOTICE! Certain parameters require special authorization.
Regulator mode
Regulator gradient
Idling speed
Stop function
Lamp test
This parameter determines if a lamp test is to be performed when the system is started.
Alternative modes: Off or On
Preset mode: On
36
7748542 10-2009
Alarm limits
TAD1350GE, TAD1351GE, TAD1352GE
Alarm threshold, high oil temperature
A warning lamp is lit at this temperature.
Min. value: 120 C (248 F)
Preset value: 125 C (257 F)
Max. value: 130 C (266 F)
Alarm threshold, high coolant temperature
A warning lamp is lit at this temperature.
Min. value: 95 C (203 F)
Preset value: 102 C (216 F)
Max. value: 103 C (217 F)
Overspeed limit
Percent above normal revolutions at which the overspeed warning is activated.
Min. value: 0 %
Preset value: 20 %
Max. value: 20 %
Alarm limits
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE
Alarm threshold, high oil temperature
A warning lamp is lit at this temperature.
Min. value: 120 C (248 F)
Preset value: 125 C (257 F)
Max. value: 130 C (266 F)
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37
Engine protection
TAD1341GE, TAD1342GE, TAD1343GE,
TAD1344GE, TAD1345GE, TAD1350GE,
TAD1351GE, TAD1352GE, TAD1353GE
Oil temperature
Determines whether engine protection is to be activated in respect of high oil temperature. A fault code
is registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
Oil pressure
Determines whether engine protection is to be activated in respect of low oil pressure. A fault code is
registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
Coolant temperature
Determines whether engine protection is to be activated in respect of high coolant temperature. A fault
code is registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
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 pressure
Determines whether engine protection is to be activated in respect of high charge air pressure. A fault
code is registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
38
7748542 10-2009
Engine protection
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE
Oil temperature
Determines whether engine protection is to be activated in respect of high oil temperature. A fault code
is registered and the engine is shut down.
TAD1650VE: a fault code is registered and an orange
or red warning lamp is lit.
Alternative modes: Yes or No
Preset mode: Yes
Coolant temperature
Determines whether engine protection is to be activated in respect of high coolant temperature. A fault
code is registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
Coolant level
Determines whether engine protection is to be activated in respect of low coolant level. A fault code is
registered and the engine is shut down.
TAD1650VE: a fault code is registered and an orange
warning lamp is lit.
Alternative modes: Yes or No
Preset mode: Yes
Charge air temperature
Determines whether engine protection is to be activated in respect of high charge air temperature. A fault
code is registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
Oil pressure
Determines whether engine protection is to be activated in respect of low oil pressure. A fault code is
registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
Piston cooling pressure
Determines whether engine protection is to be activated in respect of low piston cooling pressure. A fault
code is registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
Crankcase pressure
Determines whether engine protection is to be activated in respect of high crankcase pressure. A fault
code is registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
ECU temperature
Determines whether engine protection is to be activated in respect of high control unit temperature. A
fault code is registered and an orange or red warning
lamp is lit.
Charge pressure
Determines whether engine protection is to be activated in respect of high charge air pressure. A fault
code is registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
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39
Diagnostic Function
The diagnostic function monitors and controls that the
EMS system functions normally. The diagnostic function has the following tasks:
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:
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Inactive faults
DU (Display Unit)
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.
3 Look up the fault code in the Fault Code Register chapter and take the recommended measures.
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41
42
7748542 10-2009
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.
Reaction
Remedy
Reaction
None
Remedy
Empty the primary fuel filter
Reaction
Engine control module
reduces engine power
(unless the protection has
been shut off with the VODIA
diagnostic tool)
Remedy
Check the coolant level
Reaction
None
Fault in sensor
Remedy
Check that the coolant level
sensor cable is not damaged
Abnormal frequency
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
43
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
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
Open circuit
Fault in indicator
Reaction
None
Remedy
Check the indicator cables for
breaks and short circuits
44
Open circuit
Reaction
None
Remedy
Check that the oil pressure
sensor cable is not damaged
7748542 10-2009
Reaction
None
Open circuit
Remedy
Check that the boost temperature sensor connector is correctly installed
Reaction
Preheating is also activated
when the engine is hot
Open circuit
Remedy
Check that the coolant temperature sensor connector is
correctly installed
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
45
Reaction
Engine power is reduced or
engine stops.
Action
Check that the charge air
pressure sensor connector is
correctly installed
Reaction
None
Open circuit.
Remedy
Check that the fuel pressure
sensor connector is correctly
installed.
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
Reaction
None
Remedy
Check if it is possible to build
up pressure with the hand
pump
46
Reaction
None
Remedy
Check the supply voltage
from the control unit
7748542 10-2009
Reaction
The engine cannot be started
Remedy
Check that connections to the
ignition key/start panel have
not been damaged
Open circuit
Reaction
Engine can only be stopped
with the auxiliarystop
Remedy
Check that the starter switch
connections are not damaged
Reaction
The engine cannot be started
Remedy
Check that connections to the
ignition key/start panel have
not been damaged
Open circuit
Reaction
Engine can only be stopped
with the auxiliary stop (AUX
STOP) on engine
Remedy
Check that the starter switch
connections are not damaged
Open circuit.
Reaction
Preheating can not be activated.
Remedy
Check that the relay input
cable is not damaged.
7748542 10-2009
Reaction
Less good response from
engine
Remedy
Check the air filter
47
Reaction
None
Break
Remedy
Check that the air filter sensor
contact is correctly installed
Reaction
None
Remedy
Check the oil level
Reaction
The engine control module
limits engine output(unless
protection has been turned off
with thediagnosis tool
VODIA)
Remedy
Check the oil level
Reaction
None
Break
Remedy
Check that the cable harness
to the oil level sensor has not
been damaged
Reaction
Engine control module
reduces engine power
(unless the protection has
been shut off with the VODIA
diagnostic tool)
Remedy
Check the coolant level
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
7748542 10-2009
Reaction
Instruments and warning
lamps stop working
Remedy
Check that the 8-pin connector is 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
Reaction
Engine control module
reduces engine power
(unless the protection has
been shut off with the VODIA
diagnostic tool)
Remedy
Check oil level
Reaction
Engine stopped
Remedy
Check that the oil pressure in
the engine exceeds175 kPa
(25.4 psi)
Break
7748542 10-2009
Reaction
None
Remedy
Check that the piston cooling
pressure sensor contact is
correctly installed
49
Faulty alternator
Reaction
Problems in engine starting
Remedy
Check the supply voltage
from the control unit
Reaction
Engine runs on 5 cylinders
Abnormal sound
Reduced performance
Remedy
Check that the injector cables
are not damaged
Reaction
Engine runs on 5 cylinders
Abnormal sound
Reduced performance
Remedy
Check that the injector cables
are not damaged
50
Reaction
Engine runs on 5 cylinders
Abnormal sound
Reduced performance
Remedy
Check that the injector cables
are not damaged
7748542 10-2009
Reaction
Engine runs on 5 cylinders
Abnormal sound
Reduced performance
Remedy
Check that the injector cables
are not damaged
Reaction
Engine runs on 5 cylinders
Abnormal sound
Reduced performance
Remedy
Check that the injector cables
are not damaged
Reaction
Engine runs on 5 cylinders
Abnormal sound
Reduced performance
Remedy
Check that the injector cables
are not damaged
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
51
Reaction
None
Break
Remedy
Check that the crankcase
ventilation pressure sensor
contact is correctly installed
Reaction
None
Break
Remedy
Check that the air temperature sensor contact is correctly installed
Fault in harness
Fault in sensor
Reaction
Warning lamp lights up
Remedy
Check harness
Check sensor
Faulty actuator
Fault in MPROP
Reaction
Control unit reduces engine
power
Remedy
Contact an authorized Volvo
Penta workshop
52
Reaction
Control unit reduces engine
power
Remedy
Contact an authorized Volvo
Penta workshop
7748542 10-2009
Reaction
Control unit reduces engine
power
Remedy
Contact an authorized Volvo
Penta workshop
Reaction
None
Remedy
Check the control unit installation. Recommended ambient temperature is 50C
(122F)
Reaction
Engine control module
reduces engine power
Remedy
Check cable harness (boost
pressure sensor)
Reaction
Preheating can not be activated
Remedy
Check the cable harness
Reaction
None
Remedy
Check that the 8-pin connector is not damaged
Fault in sensor
7748542 10-2009
Reaction
Faulty values in oil pressure
and boost pressure sensors
Remedy
Check that the cable harness
to oil pressure and boost
pressure sensor has not been
damaged
53
Data Set Memory EEPROM, CIU (Code 9.8, SID 253/SPN 630)
Cause
Internal fault in control module
Reaction
Engine does not start
Remedy
Re-program the control module.
Programming faulty
Reaction
CIU returns to factory setting
Remedy
Re- program the unit
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
Remedy
Re-program the control module. If the fault remains,
change the control module
Reaction
Engine misfires
Remedy
Change engine control unit
Open circuit
Wastegate damaged
mechanically
Reaction
Warning lamp lights up
Remedy
Check that the wastegate
connector is properly
mounted
54
Reaction
Warning lamp lights up
Remedy
Check that the fan actuator is
properly mounted
7748542 10-2009
Reaction
Warning lamp lights up
Remedy
Check that the fan actuator is
properly mounted
Open circuit
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
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