EMS2 Installation ManualD16_US

Installation IIndustrial Engines 1(1) EMS 2 TAD1640GE, TAD1641GE, TAD1642GE, TWD1643GE, TAD1641VE TAD1642VE, TAD1643VE, TAD1650VE,TAD1650GE,TAD1651GE TWD1652GE, TWD1653GE, TAD1660VE, TAD1661VE, TAD1662VE TAD1640VE-B, TAD1641VE-B, TAD1642VE-B Content Safety Information ...................................................................................... 2 Installation Tools and Documentation ...................................................... 4 Special Tools ............................................................................................ 4 System Information .................................................................................... 5 EMS ........................................................................................................... 5 Control System Installation ..................................................................... 50 Connection ............................................................................................. 50 Calibration and Settings ........................................................................... 71 Parameter Setting .................................................................................. 71 Diagnostic Function ............................................................................... 92 Fault Code Register ............................................................................... 95 Alphabetical index .................................................................................. 109 47701683 10-2012 © AB VOLVO PENTA 1 Safety Information Presentation Working methods This installation manual contains information for The work must be performed by a Volvo Penta work- installing and carrying out function and performance shop or other authorized, well-equipped workshop by checks on the EMS 2 system (electronic control of the qualified and experienced personnel. injection system). These instructions refer to such personnel as fitters. This instruction manual is intended only for professio- This installation manual is intended to be used nal use. together with the operator's manual for the engine Read the instructions carefully before starting the concerned. The fitter is responsible for ensuring that installation. If the installation is performed in an incor- the system functions in accordance with these instal- rect manner, it may cause personal injury or damage lation instructions. to property and machinery. Volvo Penta disclaims all responsibility for injury to Ask your Volvo Penta dealer for help if there is any- persons or damage to property that may occur as a thing in this manual that you do not understand or are result of not following the installation guidelines, or for uncertain about. work carried out by unqualified personnel. ! This symbol is used in the manual and on the product to call attention to the fact that this is safety information. Always read such information very carefully. Safety texts in the installation manual have the following order of priority: DANGER! Indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING! Indicates a hazardous situation which, if not avoided, could result in death or serious personal injury. CAUTION! Indicates a hazardous situation which, if not avoided, could result in minor or moderate personal injury. IMPORTANT! Indicates a situation which, if not avoided, could result in property damage. NOTICE! Used to draw attention to important information that will facilitate work or operations. This symbol is used on our products in certain cases and it refers to important information in the operator's manual. Make sure that warning and information symbols on the engine are clearly visible and legible. Replace symbols that have been damaged or painted over. 2 47701683 10-2012 © AB VOLVO PENTA 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 Never expose battery compartments to open flames any arc welding is carried out. or electrical sparks. Never smoke in the vicinity of the Turn the current off at the main switches. batteries. Undo and remove the control unit connectors. Batteries generate hydrogen gas during charging, Reconnect the EMS 2 control unit connectors once which can combine with air to form an explosive mix- welding is completed and the welding equipment has ture. This gas is highly flammable and explosive. been removed. Incorrect connection of the batteries may cause sparks that in turn cause an explosion resulting in ! damage. Take care to keep clear of the engine's moving parts Do not switch battery connections when attempting to during functional checks and operations. There is a start the engine (risk for sparks) and do not lean over risk for personal injury when approaching a running the batteries. Refer to the instructions in the engine engine. Remember that loose clothing and long hair operator's manual. can fasten in rotating parts and cause serious injury. ! ! Make sure that the positive (+) and negative (-) battery Never work on an engine that is suspended from lifting cables are correctly connected to the corresponding gear (a crane or similar). battery terminals. Serious damage may be caused to ! the electrical equipment if the cables are transposed. The engine must not be run in areas where there are Refer to the wiring diagram in the engine operator's explosive materials or gases. manual. ! ! Only start the engine in well-ventilated places. If the Always wear eye protection when charging or han- engine is operated in an enclosed space, make sure dling the batteries. Battery electrolyte contains sulfu- that there is sufficient ventilation to remove the ric acid which is highly corrosive. If electrolyte comes exhaust gases and crankcase fumes from the work- into contact with bare skin, wash the exposed area place. immediately with copious amounts of clean water and soap. Then seek medical attention. If you get battery electrolyte in your eyes, flush them immediately (pref- erably using eye wash equipment) with copious amounts of clean water. Then seek immediate medi- cal attention. 47701683 10-2012 © AB VOLVO PENTA 3 Installation Tools and Documentation, Special Tools Installation Tools and Documentation Special Tools p0005125 3838619 VODIA, diagnostic 88890074 Multimeter tool VODIA, complete with cable har- Multimeter ness Refer to the VODIA operators manual when ordering separate parts. Other Special Equipment Other special equipment The tools below are used for work on the engine wire harness. The tools are not part of the Volvo Penta range, and must be ordered from AMP or Deutsch dealers. Contact Volvo Penta Quality Action Center if you have trouble finding a dealer. AMP connector: 42-pin CIU, 62-pin EMS, 2 and 3 pin Bosch etc. P0003813 P0003809 HDT-48–00 AMP 539 968 AMP 726 519 Press tool Removal tool, 1.5 mm pin width Removal tool, 0,06 inch pin width P0003811 P0003810 P0003813 AMP 726 519 AMP 929 039 AMP 238 635 Removal tool, 2.8 mm pin width Removal tool, 2.8 mm pin width Press tool P0003811 P0003814 AMP 825 514 GHW 50000 017 586 Press tool Removal tool, 2.8 mm pin width For 4.8 and 6.3 cable shoes. For GHW connector (relay box) Flat-pin connectors. 4 47701683 10-2012 © AB VOLVO PENTA System Information, EMS System Information EMS Engine control system 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 sys- tem 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 communi- cation interface comprising a CAN-link and a serial link. CAN (Controller Area Network) The CAN J1939 link handles all communication between the engine control module EMS 2 and the CIU, in addition to the diagnostics that are handled by the so called J1708/J1587 link. The CAN link is much faster than the J1708/J1587 link. The CAN link has been prepared to connect to other components with SAE J1939 protocol such as instrument panels and transmissions. If, for some reason, a fault develops on the CAN link, signals for the rpm-potentiometer and the start and stop knobs are taken over by the J1708/J1587 link. However, instrument and indicator lamps are com- pletely turned off. If a fault occurs on both links, GE engines maintain engine speed, while VE engines go to idle. The only way to shut off the engine in this case is to use the auxiliary stop (AUX-STOP) placed on the engine’s left side. 47701683 10-2012 © AB VOLVO PENTA 5 System Information, EMS CIU (Control Interface Unit) The CIU is a “translator” between the CAN bus and the customer’s own control panel. This unit has two serial communication links, one fast and one slow. The fast one is a CAN link that features a bus speed of 250 Kbit/ s. All data regarding instruments, indicator lamps, con- tacts and potentiometers are controlled by this bus. The slower J1708/J1587 link handles diagnostic infor- mation for, among other things, the flashing code. The diagnosis tool VODIA also uses the J1708/J1587 link to communicate with the system. P0002060 6 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Fuel control The engine’s fuel requirement is analyzed up to 100 Altitude correction times per second (depending on engine rpm). The The control unit is fitted with an atmospheric air pres- engine’s injection amount and injection timing is con- sure sensor and an altitude correction function for trolled electronically via fuel valves on the unit injec- engines operating at high altitudes. This function lim- tors. its the fuel volume in relation to ambient air pressure. This means that the engine always receives the cor- This is to prevent smoke, high exhaust temperature rect volume of fuel in all operating conditions, which and to protect the turbocharger from over-speeding. offers lower fuel consumption, minimal exhaust emis- sions etc. Diagnosis function The control module checks and controls the unit injec- The task of the diagnosis function is to detect and tors so that the correct amount of fuel is injected into locate disturbances within the EMS 2 system, to pro- each cylinder. It calculates and sets the injection tect the engine, and to provide information about angle. The control is primarily performed using the problems that have developed. If a malfunction is dis- speed sensors and the combined sensor for boost covered, this is announced by warning lamps, a flash- pressure/charge air temperature. ing diagnostic lamp or in plain language on the instru- The control module affects the unit injectors via an ment panel, depending on the equipment used. If a electronic signal to the unit injectors’ electromagnetic fault code is obtained as a flashing code or in plain fuel valve, which can open and close. language, this is used for guidance in any trouble- When the fuel valve is open, fuel flows through the shooting. Fault codes can also be read by Volvo’s unit injector hole and out through the fuel channel. VODIA tool at authorized Volvo Penta workshops. In Fuel is not sprayed into the cylinder in this position. case of serious malfunctions, the engine is shut down When the fuel valve closes, pressure starts to build completely, or the control unit reduces the power out- from the unit injector’s mechanically operated pump put (depending on application). A fault code is set as plunger. When sufficient pressure has developed, fuel a guide when fault tracing. is injected into the cylinder via the unit injector’s injec- tor 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. Calculating fuel quantity The amount of fuel that is sprayed into a cylinder is calculated by the control module. The calculation determines the time that the fuel valve is closed (when the fuel valve is closed fuel is sprayed into the cylin- der). The parameters controlling injected amount of fuel are: • Requested engine speed • Motor protector • Temperature • Boost air pressure 47701683 10-2012 © AB VOLVO PENTA 7 System Information, EMS In- and out signals Information from the sensors provides exact reports regarding operational circumstances and makes it possible for the control unit processor to calculate the correct injection amount, injecton timing and engine condition, among many other things. Input signals The control unit receives input signals regarding engine operational conditions along with information from the following components: - Coolant temperature sensor - Charge air pressure / charge air temperature sen- sors - Crankcase pressure sensor - Position sensor - Camshaft - Engine speed sensor - Flywheel - Cylinder 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 - Exhaust temperature sensor (TWD1643GE) 8 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Output signals The control unit uses the input signals to control the following components: - Unit injectors - Starter motor - Alternator - Main relay - Pre-heat relay - Wastegate (TWD1643GE, TAD1650VE) - Cold start valve (TWD1643GE) - Valve mechanism, internal EGR (TAD1650VE) - Electronic fan control 47701683 10-2012 © AB VOLVO PENTA 9 System Information, EMS Instruments DCU (Display Control Unit) DCU is a digital instrument panel that communicates with the engine control unit via the CAN-link. DCU has several functions, such as: Engine control - Start, stop, rpm regulation, preheating, etc. P0002932 Monitoring - Shows engine speed, charge pressure, charge tem- perature, coolant temperature, oil pressure, oil tem- perature, engine hours, battery voltage, instantane- ous 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 10 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Electrical interface General This document describes how the Volvo Penta indus- trial engines equipped with the control systems EMS and EMS2 may be controlled. There are a number of interfaces available to control the engine. The interfaces are: • Bus interface • CIU • DCU The common thing about the three first interfaces is that the engine is controlled over two serial communi- cation buses. The CIU and DCU uses the bus interface to communicate with the engine. IMPORTANT! If non Volvo Penta equipment is connected to the com- munication busses there is always a risk that the safety of the system is jeopardized. 47701683 10-2012 © AB VOLVO PENTA 11 System Information, EMS Abbrevations BAM Broadcast Announce Message CAN Controller Area Network DEF Diesel Emission Fluid EATS Engine After Treatment System EIC Engine Interface Connector EECU Engine Electronic Control Unit EMS Engine Management System EMS 2 EMS used on TAD734GE, D9, TAD125xVE, D13 and D16 engines FMI Failure Mode Identifier OEM Original Equipment Manufacturer SPN Suspect Parameter Number VP Volvo Penta Relevant dokumentation • 7748665 Electrical interface specification industrial engines EMS and EMS2 • SAE J1939-73 • SAE J1939-71 12 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Engine control interface Volvo Penta industrial engines can be controlled in three different ways. Via bus interface, CIU or DCU. The bus interface is used by those who makes there own control system that and wants to control the engine over SAE J1939 and J1587. Volvo Penta pro- vided two different systems to control the engines, CIU that provides a number of digital/analogue outputs to control the engine. And DCU that has all buttons included in the unit but still provides some digital/ analogue inputs and outputs. CIU This is the interface for those who wants to make there control panel or non bus based control unit. DCU This is the interface for those who wants a complete unit that is ready to run the engine without make any button. But the possibility to make some customization is still here. The DCU is equipped with a display that shows engine data and diagnostics translated to text. Electrical interface Bus interface 8-pole deutsch connector recepticle. Pin Description 1 CAN H 2 CAN L 3 Battery – 4 Battery + 5 Ignition and stop request if energized to run 6 Stop request energized to stop 7 J1587A 8 J1587B 47701683 10-2012 © AB VOLVO PENTA 13 System Information, EMS CIU The electrical interface to the CIU is 42-pole AMP con- nector. Pin Description Pin Description 1 Idle request 22 J1587A 2 Potentiometer ground 23 Not used 3 Potentiometer signal 24 Preheat indication(1) 4 Not used 25 Coolant level alarm 5 Not used 26 Oil pressure alarm 6 Not used 27 Battery + 7 Over speed indication(2) 28 Ignition (key switch) Buzzer (3) 8 Easy link bus 29 Governor mode request 9 Coolant temperature alarm 30 Potentiometer supply 10 Battery alarm 31 Not used 11 CAN L 32 Not used 12 CAN H 33 Tachometer 13 Gauge power supply 34 Coolant temperature gauge 14 Battery – 35 Start request 15 Frequency select(4) 36 Diagnostic indication 16 Diagnostic switch 37 J1587B 17 Preheat request(5) 38 Running indication(6) 18 Not used 39 Fuel alarm 19 Engine protection override req. 40 Oil temperature alarm 20 Oil temp gauge 41 Stop request 21 Oil pressure gauge 42 Not used There is a cable harness available with all wires con- nected that applies to the above table. All indicators shall be less than 3W. All switches are active when shorted to battery+. 1. Not for 124xGE 2. Genset only 3. Power pack only 4. Genset only 5. Not for 124xGE 6. Genset only 14 47701683 10-2012 © AB VOLVO PENTA System Information, EMS DCU Connector 1, 8-pole deutsch connector. Pin Description Pin Description 1 CAN H 5 Ignition and stop request if energized to run 2 CAN L 6 Stop request energized to stop 3 Battery – 7 J1587A 4 Battery + 8 J1587B Connector 2, 12-pole deutsch connector: Pin Description Pin Description 1 External stop 7 Throttle + (10V) 2 External Start / Ignition 8 Throttle input 3 LSS1 (Buzzer) 9 Throttle – 4 Easylink gauge power 10 LSS2 (Running indication) 5 Easylink Data 11 LSS3 (spare) 6 Easylink Ground 12 LSS4 (spare) All indicators shall be less than 3W. All switches are active when shorted to battery +. 47701683 10-2012 © AB VOLVO PENTA 15 System Information, EMS Power up sequence The system powers up when the ignition is switched on. Start A start request is addressed by the start signal. The engine will then start to crank and it will continue to do so until one of the following conditions becomes true. • The start signal goes inactive. • The engine speed exceeds a stated limit, typical about 480 rpm. • The cranking time exceeds a stated limit, typical about 20 s. 30 s for genset engines. Bus interface Associated message: J1939: Start request in VP Status J1587: Start request in PPID 98 CIU Associated hardware/input: Start request. DCU Associated hardware/input: Start request. 16 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Power down sequence To perform a power down the following sequence shall be performed: 1 Switch off the ignition 2 Send a stop request to the system. 3 When the power down sequence is finished the engine will stop communicating. Auto shutdown will power down the system if the igni- tion is switched off. Different length of time sequences are being used. (Running engine will continue to run until a stop request is sent to the system). External stop External stop is placed in the 8-pole connector on pin 6. Energized to STOP / RUN Default external stop function is set to Energized to STOP. To use the stop function as Energized to STOP, apply EMS supply voltage on Pin 6 to stop the engine. By option or changing a parameter it can be set to Energized to RUN. To use the stop function as Ener- gized to RUN, Pin 6 needs EMS supply voltage for the engine to start and run. To stop the engine EMS supply voltage needs to be removed from Pin 6. Energized to RUN on Pin5 If the function “energized to run” is used the extra stop is on pin 5 together with the ignition. The main power MUST NOT be switched off before the power down sequence is finished. 47701683 10-2012 © AB VOLVO PENTA 17 System Information, EMS Stop A stop request is addressed by the stop signal and will stop the engine. Bus interface Associated message: J1939: Stop request in VP Status J1587: Stop request in PPID 98 CIU Associated hardware/input: Stop request. DCU Associated hardware/input: Stop request. 18 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Throttle (Synchronizing/Load sharing) Versatile The driver pedal demand is realized by the throttle request signal. The signal is interpreted as a 0-100% request where 0% means idle speed and 100% maxi- mal engine speed. This demand will only be overridden if an error occur that may damage the engine or a request with the CAN-message TSC1. Genset This is used for controlling the engine speed in order to synchronize and to perform load sharing. 50% throt- tle corresponds to 1500 or 1800 rpm. Bus interface Associated message: J1939: Throttle in VP Status J1587: PPID 132 CIU Associated hardware/input: Potentiometer supply, signal and ground. DCU Associated hardware/input: Increase decrease engine speed buttons or potenti- ometer supply, signal and ground. 47701683 10-2012 © AB VOLVO PENTA 19 System Information, EMS Torque speed control It is possible to override the throttle that is sent in VP Status. This is done with TSC1. When controlling the engine speed from the gearbox (SA = 0x03) it always have the highest priority. Bus interface Associated message: J1939: TSC1 J1587: N/A CIU Associated message: J1939: TSC1 J1587: N/A DCU Associated message: J1939: TSC1 J1587: N/A 20 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Governor mode The engine is normally running in isochronal mode. If there is a need for a smoother controller this can be realized by an active droop mode signal. When the governor mode signal is active then droop functionality is added to the engine speed controller. Bus interface Associated message: J1939: Governor mode in VP Status J1587: N/A CIU Associated hardware/input: Governor mode request. DCU Associated hardware/input: Available in the menu. 47701683 10-2012 © AB VOLVO PENTA 21 System Information, EMS Idle switch Versatile If the throttle request is malfunctioning (meaning that there is an electrical fault on the potentiometer or the cable harness) then the idle switch can be used for limp home driving. If there is a fault on the pedal signal then the engine will go to idle speed. If then the idle switch first goes active (meaning that the driver has released the pedal) and then goes inactive (meaning that the driver is pressing the pedal down) then the engine will slowly ramping up the engine speed. The engine speed will be ramped up to maximal 80 % of normal maximal engine speed. When releasing the pedal the engine will immediately go down to idle speed. Genset If an idle request is sent to the engine it will go to idle speed if the engine unloaded. Bus interface Associated message: J1939: Idle request in VP Status J1587: N/A 2.11.2 CIU Associated hardware/input: Idle request. CIU Associated hardware/input: Idle request. DCU Available in the menu 22 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Preheat This function is not valid for 124xGE. When a preheat request is received the engine will activate the preheat device if the following conditions are fulfilled. • The coolant temperature is low. • The engine is not running. The preheat device will be activated for a time depend- ent on the coolant temperature. The engine will also decide, using the coolant temperature, if after heating should be used. Preheating will be terminated immediately if the driver starts cranking. It is possible for the costumer, using Volvo Penta Parameter setting tool, to choose if preheating should be activated immediately after turning on the ignition (prior to same conditions as above). Bus interface Associated message: J1939: Preheat request in VP Status J1587: N/A CIU Associated hardware/input: Preheat request. DCU Associated hardware/input: Available in the menu. 47701683 10-2012 © AB VOLVO PENTA 23 System Information, EMS Frequency select This function is only valid for genset applications. The frequency switch is used for changing the nominal engine speed (i.e. switching between 1500 and 1800 rpm). For safety reasons the frequency can only be changed when the engine is stopped. EMS2 systems To make a system reset request stop wait 2 second after the last stop request. Then change the state of frequency select to the desired engine speed. Then send a stop request within 10 seconds after the first stop. The frequency select signal must change value during the frequency change. I.e. if the engine runs at secondary speed and the frequency select signal requests primary engine speed when the first stop is issued, the signal has to be switched to secondary fol- lowed by primary engine speed, before the second stop request is issued. It is possible to change the frequency using the Volvo Penta aftermarket tool. Bus interface Associated message: J1939: Frequency select in VP Status and & diagnostic request in VP Status. J1587: N/A CIU Associated hardware/input: Frequency select. DCU Associated hardware/input: Available in the menu. 24 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Engine protection override It is possible to request engine protection override. When such a request is received the engine will deac- tivate the engine protection for a predefined time. Genset engines The engine protection is disabled as long as the request is active and for another 10s. Mobile / Versatile / Powerpack The engine protection is disabled as long as the request is active and for another 10s, but is maximized to 60 seconds. Bus interface Associated message: J1939: Engine protection override request in VP Status J1587: N/A CIU Associated hardware/input: Engine protection override request. DCU N/A 47701683 10-2012 © AB VOLVO PENTA 25 System Information, EMS Communication J1939 Communication Description of supported frames, signals and mes- sages. J1939 The following frames are supported by the EMS. See following pages. Tx = transmit, Rx = receive Identifier Signal name 164xVE 1640-42GE 1643GE 165xVE 166xVE 18E8FF00 Ack Tx Tx Tx Tx Tx 18EEFF00 Address Claimed Tx Tx Tx Tx Tx 18ECFF00 BAM Tx Tx Tx Tx Tx 18FECA00 DM1 Tx Tx Tx Tx Tx 18FECB00 DM2 Tx Tx Tx Tx Tx 18EBFF00 TP.DT Tx Tx Tx Tx Tx 0CF00400 Electronic Engine Controller 1 Drivers Demand Engine, Torque % Tx Tx Tx Tx Tx Actual Engine, Torque % Tx Tx Tx Tx Tx Engine Speed Tx Tx Tx Tx Tx 0CF00300 Electronic Engine Controller 2 Accelerator Pedal Pos. 1 Tx Tx Tx Tx Tx % Load at Current Speed Tx Tx Tx Tx Tx 18FEDF00 Electronic Engine Controller 3 Nominal friction, torque % Tx Tx 0000FEE3 Engine Configuration Engine Reference Torque Tx Tx 18FEEF00 Engine Fluid Level/Pressure 1 Fuel Delivery Pressure Tx Tx Tx Tx Tx Engine Oil Pressure Tx Tx Tx Tx Tx Coolant Pressure Coolant Level Tx Tx Tx Tx Tx 18FEE500 Engine Hours Total Engine Hours Tx Tx Tx Tx Tx 18FEEE00 Engine Temperature 1 Engine Coolant Temperature Tx Tx Tx Tx Tx Engine Oil Temperature 1 Tx Tx Tx Tx Tx 18FEF200 Liquid Fuel Economy Fuel Rate Tx Tx Tx Tx Tx 18FEE900 Fuel Consumption, Liquid Trip Fuel Tx Tx Tx Tx Tx Total Fuel Used Tx Tx Tx Tx Tx 18FEF600 Inlet/Exhaust Conditions 1 Boost Pressure Tx Tx Tx Tx Tx Intake Manifold 1 Temperature Tx Tx Tx Tx Air Inlet Pressure Tx 26 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Identifier Signal name 164xVE 1640-42GE 1643GE 165xVE 166xVE Air Filter 1 Differential Pressure Tx Exhaust Gas Temperature Tx 18EA0003 Request PGN Rx Rx Rx Rx Rx 18EA0011 Rx Rx Rx Rx Rx 18EA00EA - Rx Rx 0C000003 Torque/Speed Control 1 0C000011 0C0000E6 Override Control Mode Rx Rx Rx Rx Rx - - Rx Rx Rx - - - Rx Rx Requested Speed Control Conditions Rx Rx Rx Rx Rx - - Rx Rx Rx - - - Rx Rx Override Control Mode Priority Rx Rx Rx Rx Rx - - Rx Rx Rx - - - Rx Rx Requested Speed/Speed Limit Rx Rx Rx Rx Rx - - Rx Rx Rx - - - Rx Rx Requested Torque/Torque Limit Rx Rx Rx Rx Rx - - Rx Rx Rx - - - Rx Rx 18FEF700 Vehicle Electrical Power Battery Potential (Voltage), Switched Tx Tx Tx Tx Tx 0CFF4E00 VP Configuration (1000 ms) Idle engine speed Tx Tx Tx Tx Tx Start position: 1 Length: 2 bytes Resolution: 0.125 rpm/bit Maximum engine speed Tx Tx Tx Tx Start position: 3 Length: 2 Resolution: 0.125 rpm/bit 0CFF4700 VP Engine industry (50 ms) Preheat indication Tx Tx Tx Tx Tx Start position: 1.1 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available Running indication Tx Tx Tx Tx Tx Start position: 1.3 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available 47701683 10-2012 © AB VOLVO PENTA 27 System Information, EMS Identifier Signal name 164xVE 1640-42GE 1643GE 165xVE 166xVE Buzzer Tx Tx Tx Tx Tx Start position: 3.1 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available Engine protection override ind. Tx Tx Tx Tx Tx Start position: 3.7 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available General lamp test Tx Tx Tx Tx Tx Start position: 4.1 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available Buzzer test/Lamp test Tx Tx Tx Tx Tx Start position: 4.3 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available 0CFF4611 VP Status (20 ms) Start request Rx Rx Rx Rx Rx Start position: 1.1 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available Stop request Rx Rx Rx Rx Rx Start position: 1.3 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available Governor mode request Rx Rx Rx Rx Rx Start position: 1.5 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available Idle speed select Rx Rx Rx Rx Rx Start position: 1.7 Length: 2 bits 0 = Normal operation 1 = Idle speed request 2 = Error indication 3 = Not available 28 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Identifier Signal name 164xVE 1640-42GE 1643GE 165xVE 166xVE Frequency select NA Rx Rx NA NA Start position: 2.1 Length: 2 bits 0 = Primary engine speed 1 = Secondary engine speed 2 = Error indication 3 = Not available Preheat request Rx Rx Rx Rx Rx Start position: 2.5 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available Engine protection override Rx Rx Rx Rx Rx Start position: 2.7 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available Accelerator pedal position Rx Rx Rx Rx Rx Start position: 3 Length: 2 bytes Resolution: 0.097752 (100/1023) %/bit 0xFEFF = error indication 0xFFFF = not available Fuel disable request Rx Rx Start position: 5.1 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available 18FEFF00 Water in Fuel Indicator - WFI Water in Fuel Indicator Tx Tx Tx Tx Tx 18FE5600 AT1 SCR Reagent Tank 1 Information - AT1T1l AT1 SCR Tank Level (SPN 1761) Tx Start position: 1.1 Length: 8 bits 0% = Empty Tank 100% = Full Tank AT1 DEF Tank Low Level Indicator (SPN Tx 5245) Start position: 5.6 Length: 3 bits 000: off 001: on - Solid 100: on - Fast blink (1Hz) 47701683 10-2012 © AB VOLVO PENTA 29 System Information, EMS Identifier Signal name 164xVE 1640-42GE 1643GE 165xVE 166xVE AT1 SCR Operator Inducement Severity Tx Start position: 6.6 Length: 3 bits 000: No Inducement active 001: Inducement Severity 1 010: Inducement Severity 2 011: Inducement Severity 3 100: Inducement Severity 4 101: Inducement Severity 5 18FEE400 Shutdown (EPS) Engine Protection System has Shutdown Tx Engine Start position: 5.1 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available Engine Protection System Approaching Shut- Tx down Start position: 5.3 Length: 2 bits 0 = Inactive 1 = Active 2 = Error indication 3 = Not available 0CFEF500 Ambient Condition Ambient Air Temp Tx 0CFD6E00 SCR1 Average Catalyst Reagent Consumption Tx Commanded Catalyst Reagent Consumption Tx NOTICE! The EMS does not support the address claim procedure and will always have source address 0x00. The EMS will however respond to an address claim request. 30 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Location of Sensors Location of Sensors TAD1640GE, TAD1640VE-B, TAD1641GE, TAD1641VE, TAD1641VE-B, TAD1642GE, TAD1642VE, TAD1642VE-B, TAD1643VE 1 2 3 11 4 10 5 12 6 9 8 7 14 13 P0002058 1 Coolant level sensor, in expansion tank 8 Water in fuel sensor 2 Charge air pressure and temperature sensor 9 Oil level and temperature sensor 3 Air filter indicator 10 Fuel pressure sensor 4 Flywheel position and engine speed sensor 11 Crankhouse pressure sensor 5 Fuse 12 Coolant temperature sensor 6 Aux stop 13 Piston cooling pressure sensor (not TAD1650/51GE) 7 Oil pressure sensor 14 Camshaft position sensor 47701683 10-2012 © AB VOLVO PENTA 31 System Information, EMS Location of Sensors TWD1643GE 1 2 3 4 10 5 6 9 7 11 8 15 12 14 13 P0002059 1 Coolant level sensor, in expansion tank 9 Oil level and temperature sensor 2 Charge air pressure and temperature 10 Crankhouse pressure sensor sensor 3 Oil pressure sensor 11 Coolant temperature sensor 4 Airfilter indicator 12 Exhaust temperature sensor 5 Aux stop 13 Piston cooling pressure sensor 6 Fuse 14 Flywheel position and engine speed sensor 7 “Water in fuel” sensor 15 Camshaft position sensor 8 Fuel pressure sensor 16 Solenoid valve, drainage, water trap (optional), not shown in illustration 32 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Location of Sensors TAD1650VE 1 2 3 9 4 10 7 8 5 66 12 11 P0005187 1 Crankhouse pressure sensor 7 Oil level and temperature sensor 2 Charge air pressure and temperature sensor 8 Water in fuel sensor 3 Flywheel position and engine speed sensor 9 Fuel pressure sensor 4 Fuse 10 Coolant temperature sensor 5 Aux stop 11 Piston cooling pressure sensor 6 Oil pressure sensor 12 Camshaft position sensor 47701683 10-2012 © AB VOLVO PENTA 33 System Information, EMS Location of Sensors TAD1650GE, TAD1651GE 1 Coolant level sensor, in expansion tank 8 Water in fuel sensor 2 Charge air temp and pressure sensor 9 Oil level and temp sensor 3 Air filter indicator 10 Fuel pressure sensor 4 Crank sensor (RPM) 11 Crankhouse pressure sensor 5 Fuse 12 Coolant temperature sensor 6 Aux stop 13 Camshaft position sensor 7 Oil pressure sensor 34 47701683 10-2012 © AB VOLVO PENTA System Information, EMS Location of Sensors TAD1660VE, TAD1661VE, TAD1662VE 1 2 3 4 11 5 10 6 7 9 8 12 13 14 P0014323 47701683 10-2012 © AB VOLVO PENTA 35 System Information, EMS 1 Coolant level sensor, in expansion tank 9 Oil level and temp sensor 2 Connection to SCR system 10 Fuel pressure sensor 3 Charge air pressure and temperature 11 Crankhouse pressure sensor 4 Air filter indicator 12 Fuel pressure sensor 5 Flywheel sensor, speed and position 13 Camshaft position sensor 6 Fuses for SCR system 14 Humidity sensor 7 Aux stop 8 Water in fuel sensor 36 47701683 10-2012 © AB VOLVO PENTA 10 13 15 H L 11 12 14 A B 8 16 18 1 2 1 2 3 4 5 6 7 8 1 2 17 1 2 3 4 5 6 R W W SB BL 7 Y/W W/SB R 2,5 GR/Y W/SB SB 2,5 CAN 2 R/BL 1,5 Y SB 2 1234567 19 R Y 1 SB 86 Y/SB 1 85 SB 4 P2 R/BL 1,5 2 87 R 1,5 30 3 3 5 9 R 1,5 4 R B 1 (1) (2) 5 SB 4 R/BL P2 C 1 4 6 SB 47701683 10-2012 © AB VOLVO PENTA SB (3) (4) B SB (2) (1) P2 CAN j1939 1 R 2,5 CAN 2 (1) (2) Y GN/R SB1,0 BL/GN GN/SB R 1,0 SB 1,0 BN/OR GR/W LBN GR/R R/BL 1,5 R/BL 1,5 SB 1,5 SB 1,5 SB 1,5 R/Y OR Y/W GN/W BL/W BL/GR GR/Y BL/OR 11 31 3 4 17 18 27 28 16 23 14 10 8 52 56 57 60 51 55 58 59 61 29 25 h l h l 33 34 32 BA 7 11 47 22 15 29 31 45 46 37 38 40 48 56 32 16 24 59 60 8 33 34 27 58 57 + - - SB W BL OR R 1,5 W 1,5 W 1,5 W 1,5 W 1,5 W 1,5 W 1,5 W 1,5 W 1,5 31 SB 1,0 Y/SB W/SB 29 SB 1,5 BN/OR OR/SB GR/SB GR/SB GR/OR VO/SB GR/GN R/BL 1,5 4 SB SB 1 3 2 1R R 3 1234 2P P4 CAPILLERING 30 STOPPER x8 25 20 4 MAIN RELAY HOLD 1 3 CYL. 1 P2 2 1 CYL. 2 n n 24 CYL. 3 Wiring Diagram 28 27 TAD1642VE, TAD1642VE-B R/Y R 25 R/BL R/BL R 2,5 CYL. 4 SB 25 SB 2,5 KL 15 50 12345 CYL. 5 23 B+ B- SB 25 31 M 30 21 G CYL. 6 R 25 TAD1641VE, TAD1641VE-B, TAD1642GE, TAD1640GE, TAD1640VE-B, TAD1641GE, 26 P0004301 22 37 System Information, EMS System Information, EMS 1 Sensor, oil level 19 Main relay 2 Sensor, fuel pressure 20 Main circuit breaker 10 A 3 Sensor, crankhouse pressure 21 Starter motor 4 Sensor, coolant temperature 22 Battery (24 V) 5 Sensor, coolant level 23 Alternator 6 Piston cooling pressure sensor 24 Pre-heating 7 Sensor, water in fuel 25 Relay pre-heating 8 Connector (not used) 26 Unit injector (Cyl. 1-6) 9 Extra stop 27 Sensor, flywheel 10 J1939 CAN (bus) 28 Sensor, camshaft 11 Battery negative 29 Sensor, charge air pressure/temperature 12 Battery plus 30 Air filter indicator 13 Voltage after key 31 Sensor, oil pressure 14 Stop button (press button) 32 Connector A 15 J1587 (bus) 33 Connector B 16 Jumper 34 Control unit, EMS 2 17 Aux stop 35 Connector (not in usej) 18 VODIA output 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 otherwise stated. 38 47701683 10-2012 © AB VOLVO PENTA System Information, EMS TWD1643GE 47701683 10-2012 © AB VOLVO PENTA 39 System Information, EMS 1 Sensor, oil level 20 Main fuse breaker 10 A 2 Sensor, fuel pressure 21 Starter motor 3 Sensor, crankhouse pressure 22 Battery (24 V) 4 Sensor, coolant temperature 23 Alternator 5 Sensor, coolant level 24 Pre-heating 6 Sensor, piston cooling pressure 25 Relay pre-heating 7 Sensor, water in fuel 26 Unit injector (Cyl. 1-6) 8 Connector (not in use) 27 Sensor, flywheel 9 Extra stop 28 Sensor, camshaft 10 J1939 CAN (bus) 29 Sensor, charge air pressure/temperature 11 Battery minus 30 Air filter indicator 12 Battery plus 31 Sensor, oil pressure 13 Voltage after key 32 Thermostat by-pass valve 14 Stop button (press button) 33 Wastegate valve 15 J1587 (bus) 34 Sensor, exhaust temperature 16 Jumper 35 Connection A 17 Aux stop 36 Connection B 18 VODIA input (diagnosis conn) 37 Engine control unit, EMS 2 19 Main relay 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 otherwise stated. 40 47701683 10-2012 © AB VOLVO PENTA 11 1 2 7 CAN BATT 1708 J1939 BATT- SWITCHED J1587 P0004304 CAN 2 H L BATT+ STOP A B 10 26 1 2 3 4 5 6 7 8 12 3 4 5 6 SB R W/SB W 1 2 Y/W GR/Y SB 2,5 R 2,5 R/BL 1,5 GR/SB W W/SB 23 5 28 6 86 Y/SB 85 1 1 2 2 1 R/BL 1,5 87 2 SB Y 30 R 15 1 2 3 4 5 6 7 3 R SB Y 4 5 8 21 Y 1,0 R/BL R/BL 1,5 SB SB 2 SB 2 1 1 22 25 12 15 SB SB 4 1 4 4 R/BL 1,0 SB R R 2 3 2 2 1 1 2 1 P P P 47701683 10-2012 © AB VOLVO PENTA 27 GN/SB GN/W BL/GN GN/R R 1,0 SB 1,0 GR/R BN/OR LBN GR/R SB 1,0 Y BL/W BL/GR Y 1,0 GN Y/SB OR 1,0 R/W R/BL 1,5 R/BL 1,5 BN 1,0 SB 1,5 SB 1,5 SB 1,5 Y/W GR/Y 3 4 11 16 17 18 28 27 23 14 10 8 52 56 30 38 29 25 37 57 60 7 58 59 61 51 55 h l h h l CONNECTOR B CONNECTOR A b a R 2,5 SB 2,5 31 11 7 47 22 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24 59 62 60 61 8 33 34 27 58 57 + - GR/OR SB 1,0 R 1,0 BN/OR GR/GN OR/SB GR/SB GR/SB VO/SB Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y 1,0 Y/SB W/SB W BL R/BL 1,5 SB 1,5 9 R 3 2 SB 1 P 4 4231 4 3 MAIN RELAY HOLD 4231 24 2 1 Cyl 1 17 SB 19 4 1 BN 1,0 R/BN 1,0 OR 1,0 R 3 4 3 TAD1650VE P2 1 2 1 2 R/BL 1,5 n n R 25 BL/OR 2 1 18 Cyl 2 SB 2,5 R/W Y/SB R 2,5 13 14 4 3 20 12 3 4 5 SB 25 2 1 B+ B- Cyl 3 SB 25 G M 30 4 31 3 4 3 R 25 2 1 2 Cyl 4 4 3 2 1 1 Cyl 5 4 3 2 1 Cyl 6 16 41 System Information, EMS System Information, EMS 1 Battery (24 V) 15 Sensor, piston cooling pressure 2 Main switch 16 Unit injector (cyl. 1-6) 3 Starter motor 17 Pre-heat relay 4 Alternator 18 Circuit breaker 5 Main relay 19 Main automatic circuit breaker 10 A 6 Aux stop 20 Pre-heater 7 Connector, engine interface 21 Sensor, coolant level 8 Sensor, coolant temperature 22 Sensor, oil level 9 Sensor, charge air pressure/temperature 23 Sensor, water in fuel 10 VODIA socket (diagnosis socket) 24 Sensor, oil pressure 11 Connector, not used 25 Sensor, fuel pressure 12 Sensor, crankhouse pressure 26 Internal EGR 13 Sensor, camshaft 27 Control unit, EMS 14 Sensor, flywheel 28 Wastegate valve Cable colors BL = Blue LBL = Light blue BN = Brown LB = Light brown N GN = Green GR = Gray OR = Orange P = Pink R = Red SB = Black VO = Violet W = White Y = Yellow Wire cross-section = 0.75 mm² unless otherwise stated. 42 47701683 10-2012 © AB VOLVO PENTA System Information, EMS TAD1651GE P0014126 47701683 10-2012 © AB VOLVO PENTA 43 System Information, EMS 1 Battery (orange indication) (24 V) 17 Pre-heat relay 2 Starter motor 18 Circuit breaker 3 Alternator 19 Fuse, 10 A 4 Main relay 20 Pre-heater 5 AUX stop 21 Sensor, coolant level 6 Control unit, EMS2 22 Sensor, oil level 7 Connector, engine interface 23 Sensor, water in fuel 8 Sensor, Coolant temperature 24 Sensor, oil pressure 9 Sensor, charge air pressure/temp. 25 Sensor, fuel pressure 10 VODIA output 26 Air filter indicator 11 Connector, no use 27 Electrical fan 12 Sensor, crankhouse pressure 28 13 Sensor, camshaft 29 Valve, cold start 14 Sensor, flywheel 30 Valve, wastegate 15 Sensor, piston cooling pressure 31 Connection box 16 Unit injector (cyl. 1-6) 32 Sensor, exhaust temperature Cable colors BL = Blue LBL = Light blue BN = Brown LB = Light brown N GN = Green GR = Grey OR = Orange P = Pink R = Red SB = Black VO = Purple W = White Y = Yellow Cabel cross section= 0,75 mm² unless otherwise stated. 44 47701683 10-2012 © AB VOLVO PENTA System Information, EMS TAD1660VE, TAD1661VE, TAD1662VE TAD1660VE, TAD1661VE, TAD1662VE 0,75 SB 0,75 SB 0,75 SB 0,75 GR/OR B C A E D F B C A E D F 29 1 BN 1 CONNECTOR A CONNECTOR B 28 49 31 11 0,75 SB 1 SB 0,75 GN/SB P1/4 3 0,75 R 1R 0,75 GN/W BC AED F 7 4 0,75 R 0,75 BL/GN 0,75 BN/OR n 31 47 0,75 R 27 0,75 GN/GR 0,75 BL/OR 22 11 0,75 SB 0,75 GN/R 2 5 P1/4 15 29 16 0,75 OR 0,75 GN P P 35 39 0,75 BL 0,75 SB 0,75 R 0,75 OR/SB 26 45 46 n 0,75 GR/SB 1R 0,75 R 1 BL/R 17 0,5 GR/W 25 37 38 n 0,75 OR/SB 1 SB 0,75 SB 18 1Y Y 0,75 SB 36 0,75 R 1Y 0,75 SB 40 30 3 4 44 48 1/4 P 52 56 0,75 GR/R 1 SB 28 0,75 BN/OR 28 32 27 24 1R 12 16 0,75 BL 5 0,75 VO 20 24 CYL.6 CYL.5 CYL.4 CYL.3 CYL.2 CYL.1 1 1Y M 1 2 3 4 0,75 GR 6 24 IC 5 NCV NCV NCV NCV NCV NCV 2 2 2 2 2 2 4 4 4 4 4 4 0,75 W 7 3 1 3 1 3 1 3 1 3 1 3 1 SV SV SV SV SV SV 23 0,75 SB 1Y 1Y 0,75 SB 10 1Y 0,75 Y 1 2 3 4 5 6 7 1Y 8 1Y 1Y 1Y 0,75 SB 59 1Y 1Y 1Y 62 1Y 0,75 P 8 1Y 1Y 22 21 H L 0,75 BN/P 60 11 1Y 1Y 1Y 61 0,75 BL/W 0,75 Y/SB J1939 H 1 2 3 4 5 6 52 56 H L 0,75 BL/GR 8 J1939 L 1,5 BL/R 0,75 GN BAT+MAIN REL. 0,75 W/SB 38 33 MAIN RELAY HOLD 0,75 W 0,75 Y/SB J1708 A 0,75 W/SB 29 0,75 BL/R 0,75 W J1708 B 34 1 OR 10 25 0,75 BL 0,75 R/W 27 37 1,5 BL/R 1,5 BL/R 9 58 57 1,5 BL/R 1,5 BL/R 1,5 SB 60 57 23 1 BN 7 0,75 BL/W %RH 23 43 0,75 BN 1,5 SB NTC 1,5 BL/R 58 1,5 SB 59 1,5 SB 61 0,75 Y/W 51 0,75 Y/GR 12 55 J1939 H 1 2 3 4 5 6 7 8 22 2,5 SB 2,5 R J1939 L BAT.- BAT.+ BAT. SWITC. G 1 BL/R STOP 0,75 W J1708 A 0,75 W/SB J1708 B 0,75 R 25 SB 2,5 SB 13 25 R 0,75 R BAT.+ 1 2 3 4 5 6 0,75 W/SB J1708 B 4 SB 0,75 SB BAT.- CAN3 HIGH 0,75 W J1708 A 21 SB 15 CAN3 LOW M SW R 87 30 87a 20 25 SB R 86 85 19 17 1,5 R 0,75 R 4R 2,5 R 2,5 R 18 4 SB 4R 4R 14 16 25 R 1 BN 4 3 2 1 4 3 2 1 1 OR 1 BL/R 1 BL/R 1 SB 47701683 10-2012 © AB VOLVO PENTA 45 System Information, EMS 1 Sensor, oil level / temperature 17 Fuse, 10 A 2 Sensor, fuel pressure 18 Fuse, 30 A 3 Sensor, crankhouse pressure 19 Starter motor 4 Sensor, coolant temperature 20 Main switch 5 Sensor, oil pressure 21 Battery 6 Throttle 22 Alternator 7 Switch, coolant level 23 Humidity sensor 8 Water in fuel connector 24 Unit injector (cyl. 1-6) 9 Stop button 25 Sensor, crank 10 VGT control valve 26 Sensor, camshaft 11 6-pole EATS connector 27 Air filter indicator 12 8-pole engine connector 28 Electric fan 13 6-pole diagnosis connector 29 Sensor, air inlet pressure / intake mani- 14 2-pole EATS connector fold temperature 15 Main relay 30 Control unit EMS2 16 4-pole pre-heat connector 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 otherwise stated. 46 47701683 10-2012 © AB VOLVO PENTA System Information, EMS CIU (Control Interface Unit) CIU (Control Interface Unit) 47701683 10-2012 © AB VOLVO PENTA 47 System Information, EMS 1 Key switch, operating current (15+) 16 Alarm, low coolant level 2 RPM-potentiometer 17 Fuel alarm 3 Tachometer (code 14) 18 Diagnostic lamp 4 Oil pressure, instrument 19 Overspeed indication (GE) 5 Oil temperature, instrument 20 Operation indicator 6 Coolant temperature, instrument 21 Preheating indication 7 Instrument illumination 22 Preheating contact 8 Idle contact, two position 23 8-pin Deutsch connecting plug, engine interface 9 1500/1800 contact, two position 24 Governor contact 10 Start switch, spring return 25 Battery voltage alarm 11 Stop switch, spring return 26 Termination resistance 120 Ohm 12 Diagnosis contact, spring return 27 8-pin Deutsch connecting socket 13 Alarm, low oil pressure 28 Contact, engine protector disconnect 14 Alarm, high oil temperature 29 Easy Link connector block 15 Alarm, high coolant temperature 30 Control Interface Unit (CIU) Cable colors BL = Blue LBL = Light blue BN = Brown LBN = Light brown GN = Green GR = Grey OR = Orange P = Pink R = Red SB = Black VO = Purple W = White Y = Yellow Cable cross section =0.75 mm2 unless other-wise stated. 48 47701683 10-2012 © AB VOLVO PENTA System Information, EMS DCU (Display Control Unit) 12345678 8 11 W/SB Y/W BL 2,5 R 2,5 GR/Y SB 2,5 R/BL 1,5 W 1 Y/W 2 GR/Y 3 SB 2,5 4 R 2,5 5 R/BL 2,5 6 BL 2,5 7 W W/SB R/BL 1,5 8 SB 2,5 BL 2,5 W/SB GR/Y R 2,5 3 Y/W W 1 1 1 VO 12345678 9 D 2 4 R/Y C 2 1 2 3 4 5 6 7 8 10 U SB/Y 3 4 R/BL 5 Y 1 5 3 SB 2 6 7 GN/R 8 GN/Y 6 9 GN/SB 7 10 SB/VO 11 SB/GR 12 SB/W P0004305 1 Stop contact Cable Colors 2 Start contact BL = Blue 3 1-pin connector LBL = Lightblue BN = Brown 4 Horn, buzzer alarm LBN = Lightbrown 5 Easy Link connector GN = Green GR = Grey 6 RPM-potentiometer OR = Orange 7 Indicator engine operation P = Pink R = Red 8 Deutsch 8-pin connector, engine interface SB = Black 9 Deutsch 8-poligt connector, engine interface VO = Violet W = White 10 Termination resistance 20 Ω Cable area = 0.75 mm2 unless 11 DCU (Display Control Unit) otherwise specified. 47701683 10-2012 © AB VOLVO PENTA 49 Control System Installation, Connection Control System Installation Connection General • The installation must be prepared for well and car- ried out with the greatest care. • Secure the connecting cable between the engine and instrument panel with clamps. Bear in mind that connector blocks must be mechanically secured so that they are not exposed to any pulling forces. • The cables must not be run close by hot engine components or close to any other heat source. Ensure that the cables are protected from mechan- ical wear, sharp edges and water splashes. If nec- essary, the cables can be run through conduits. • As far as possible, avoid splices in the system wir- ing. The cables and any splices must be accessible for inspection and service. NOTICE! Connectors must be assembled “dry”, they must not be filled with petroleum jelly or similar. 50 47701683 10-2012 © AB VOLVO PENTA Control System Installation, Connection Power supply NOTICE! The engines are equipped with a 2-pole elec- trical system. This means that the positive and nega- tive cables from the battery must be connected to the starter motor terminals. Thepositive 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 con- nected directly to terminal 31 on the starter motor. Refer to the illustration below. 30 31 P0003815 47701683 10-2012 © AB VOLVO PENTA 51 Control System Installation, Connection Battery specifikation Max. battery 2x220 Ah (series connected), 1150 A CCA EN. Battery charging Standard for all engines is that batteries are supplied with power from the alternator. Battery cable cross-section area The total length (L) of the positive och negative cables determines the cable cross sectional area (A). Max L (m) 8 10 13 (ft) 26.2 32.8 42.6 Min A (mm2) 70 95 120 (in2) 0.11 0.15 0.19 WARNING! Due to fire risk, the cable area should never be less than 70 mm2 (0.1 inch2). 52 47701683 10-2012 © AB VOLVO PENTA Control System Installation, Connection TWD1643GE NOTICE! All engines are equipped with a 2-pole elec- trical system. This means that the positive and nega- tive cables from the battery must be connected to the starter motor terminals. The battery positive cable may be run via a main switch to the positive terminal. The battery negative cable must be connected directly to the negative terminal. Refer to the illustration below. Battery specification Max. battery 2x220 Ah (series connected), 800 A CCA DIN. Battery charging Standard for all engines is that batteries are supplied with power from the alternator Battery cable cross-sectional area The total length (L) of the positive and negative cables determines cable cross sectional area (A). NOTICE! The negative cable may have a maximum length equivalent to that of the positive cable. Max L (m) 8 10 13 (ft) 26.2 32.8 42.6 Min A (mm2) 70 95 120 (in2) 0.11 0.15 0.19 WARNING! Due to fire risk, the cable area should never be less than 70 mm2 (0.1 inch2). 47701683 10-2012 © AB VOLVO PENTA 53 Control System Installation, Connection CIU TAD1640GE, TAD1641GE, TAD1642GE, TAD1650GE, TAD1651GE, TWD1643GE B C D A E F P0004306 A 8-pin Deutsch connector, from wire harness to engine D For the connection cable, refer to the Instruments page 67 section. B Connectors, analog instruments E 8-pin Deutsch connector C 3-pin Deutsch connector, Easy Link instrument F Extension cables, available in the following lengths: 3, 5, 7, 9, and 11 m 54 47701683 10-2012 © AB VOLVO PENTA Control System Installation, Connection Engine control Refer to System Information page 37 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 120 rpm: 0.3–1.9 V (preset value 1.17 V) Nominal revolutions plus 120 rpm: 1.9–4.7 V (preset value 4.5 V) A A B C 1.17 V 2.84 V 4.5 V P0005827 P0005828 47701683 10-2012 © AB VOLVO PENTA 55 Control System Installation, Connection 1500/1800 rpm switch Two-position contact. This function allows a frequency change from 50 to 60 Hz. Idle switch Two-position contact. Closed contact provides idle rpm. Droop value switch Two-position contact. The switch must be closed to provide rpm droop value. Primary control switch Two-position contact. Contact, pre-heating Two-position contact. 56 47701683 10-2012 © AB VOLVO PENTA Control System Installation, Connection CIU TAD1640VE-B, TAD1641VE, TAD1641VE-B, TAD1642VE, TAD1642VE-B, TAD1643VE, TAD1650VE A 8-pin Deutsch connector, from wire harness to engine D For the connection cable, refer to the Instruments page 67 section. B Connectors, analog instruments E 8-pin Deutsch connector C 3-pin Deutsch connector, Easy Link instrument F Extension cables, available in the following lengths: 3, 5, 7, 9, and 11 m 47701683 10-2012 © AB VOLVO PENTA 57 Control System Installation, Connection Engine control Refer to System Information page 37 CIU NO = normally open NC = normally closed A Start lock The start lock switch is used to connect the system power, pre-heating and start and stop functions. B Engine system voltage start current (control unit) is 10 A. Ensure that other components in the installation are dimensioned for this current load. C D P0003965 A Stop contact B ON contact C Start lock D Pre-heating contact Start lock positions I Position 0: engine switched OFF Position I: system voltage ON Position II: pre-heating ON (spring return) Position III: start motor ON (spring return) Position S: stop function ON (spring return) A B C D P0003966 E A Pre-heating B Start C Batt + D 15 start lock E Stop 58 47701683 10-2012 © AB VOLVO PENTA Control System Installation, Connection Control switch Two-position contact. Accelerator pedal Idle: 0.3 1.9 V (preset value 1.17 V) Full throttle: 1.9 4.7 V (preset value 4.5 V) If an accelerator pedal with different resistance and voltage values is used, the control unit must be re-cali- brated using the parameter tool; refer to Connection of special tool VODIA page 71. Idle switch The accelerator pedal has an integral idle switch that acts as an emergency device if the accelerator pedal A potentiometer becomes defective. When the accelerator pedal is depressed, a contact is B 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 47701683 10-2012 © AB VOLVO PENTA 59 Control System Installation, Connection DCU B C A P0005826 A 8-pin connector from the engine wire harness. B 3-pin Deutsch connector, Easy Link instrument C Connectors, analog instruments (options) 60 47701683 10-2012 © AB VOLVO PENTA Control System Installation, Connection DCU (Display Control Unit) The DCU is connected via the 8-pin databus connector block. Display (optional) Switch type: closing (NO), spring loaded. Stop switch (optional) Switch type: closing (NO), spring loaded. Warning and control lamps (options) Running indication: Max. power 3 W Voltage 24 V 47701683 10-2012 © AB VOLVO PENTA 61 Control System Installation, Connection Easy Link Instruments For parallel connection of up to 20 extra VDO instru- ments. 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: GE engines • Tachometer/operating hours • Coolant temperature • Oil pressure • Oil temperature • Battery voltage VE engines • Tachometer/operating hours • Coolant temperature • Oil pressure • Oil temperature • Charge air pressure • Battery voltage • Alarm monitor 62 47701683 10-2012 © AB VOLVO PENTA Control System Installation, Connection Rpm-potentiometer TAD1640GE, TAD1641GE, TAD1642GE, TAD1650GE, TAD1651GE, TWD1643GE Genset engines The values from the rpm potentiometer in, in or output signal from the connection to an external load distri- bution system can be set in the DCU. Nominal revolutions minus 120 rpm: 0–10 V (preset value 1 V) Nominal revolutions plus 120 rpm: 0–10 V (preset value 9 V) It is possible to invert the signal; see diagram. A A B B C C 1V 5V 9V 1V 5V 9V P0005824 P0005825 A Nominal revolutions + 120 rpm A Nominal revolutions + 120 rpm B Nominal revolutions (1500/1800 rpm) B Nominal revolutions (1500/1800 rpm) C Nominal revolutions - 120 rpm C Nominal revolutions - 120 rpm 47701683 10-2012 © AB VOLVO PENTA 63 Control System Installation, Connection TAD1641VE, TAD1642VE, TAD1643VE, TAD1650VE Versatile engines It is possible to invert the throttle signal; see the dia- gram below. P0005815 P0005816 Max. potentiometer value: 0–10 V (preset value 9V) Min. potentiometer value: 0–10 V (preset value 1V) 64 47701683 10-2012 © AB VOLVO PENTA Control System Installation, Connection Warning and Indication Lamps The warning and control lamps below are available. Specification for all lamps: Max. power 3 W Voltage 24 V Refer to the CIUSystem Information page 37. • Alarm, low oil pressure • Alarm, high oil temperature • Alarm, high coolant temperature • Alarm, low coolant level • Alarm, low fuel level • Alarm, low battery voltage • Diagnostic lamp • Pre-heat indicator 47701683 10-2012 © AB VOLVO PENTA 65 Control System Installation, Connection The warning and control lamps below are available. Specification for all lamps: Max. power 3 W Voltage 24 V Refer to the CIUSystem Information page 37. • Alarm, low oil pressure • Alarm, high oil temperature • Alarm, high coolant temperature • Alarm, low coolant level • Alarm, low fuel level • Alarm, low battery voltage • Diagnostic lamp • Pre-heat indicator 66 47701683 10-2012 © AB VOLVO PENTA Control System Installation, Connection Instruments Easy Link Instrument (option) Refer to the System Information page 37 for the engine concerned. For parallel connection of up to 20 extra VDO instru- ments. 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 Securing bracket P0005053 P0005052 Extension cable, 3-pole, 1 m P0005051 A 3-pin connector B 3-pin connectors C CIU wiring harness 47701683 10-2012 © AB VOLVO PENTA 67 Control System Installation, Connection Instrument, analog (option) Refer to the System Information page 37 for the engine concerned. Tachometer Use Volvo Penta standard tachometer, graduations 0– 2600 rpm. Setting code 14. Refer to installation instructions. P0003961 Oil pressure gauge Use Volvo Penta oil pressure gauge, graduations 0– 10 bar (0–145 psi). P0003961 Oil temperature gauge Use Volvo Penta oil temperature gauge, graduations 40–150 °C (104–302 °F). P0003961 68 47701683 10-2012 © AB VOLVO PENTA Control System Installation, Connection Coolant temperature gauge Use Volvo Penta oil temperature gauge, graduations 40–150 °C (105–300 °F). Diagnostics switch Switch type: closing (NO), spring loaded. For reading fault codes, refer to the Calibration and Settings page 92 chapter. Contact, pre-heater Switch type: closing (NO), spring loaded. This contact activates the pre-heating. P0003961 47701683 10-2012 © AB VOLVO PENTA 69 Control System Installation, Connection Synchronizing Engine Speed TAD1640GE, TAD1641GE, TAD1642GE, TWD1643GE Synchronization/load distribution The system is adapted for GAC synchronization and load distribution. Use the EAM122 interface module when connecting to this system. When this system is used, voltage levels must be adjusted simultaneously with VODIA, according to the below. NOTICE! The EAM122 interface module is not sold by Volvo Penta. Contact a GAC (Governors of America Corporation) dealership. A B A C B C 0.7 V 2.75 V 4.8 V P0005829 A Nominal revolutions +120 rpm B Nominal revolutions (1500/1800 rpm) C Nominal revolutions –120 rpm P0003964 A Rpm control (GN/NO) B Rpm control (GN/SB) C Contact to (R/BL 1.5) 70 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting Calibration and Settings Parameter Setting Connection of special tool VODIA Connection of special tool VODIA TAD1640GE, TAD1641GE, TAD1642GE, Function TAD1641VE, TAD1642VE, TAD1643VE It is possible to read and adjust parameters with the VODIA tool, part no.3838619, as described in the fol- lowing pages. The VODIA tool is connected to the diagnostics socket, a 6-pin connector; refer to VODIA user instructions for instructions. P0005817 TAD1650VE P0001170 47701683 10-2012 © AB VOLVO PENTA 71 Calibration and Settings, Parameter Setting Adjustable parameters TAD1640GE, TAD1641GE, TAD1642GE, TAD1650GE, TAD1651GE, TWD1643GE NOTICE! Some parameters require special authoriza- tion. Primary regulator mode Indicated engine rpm inverted value Selects the regulator to be used when the regulator Selects the regulator to be used when the regulator contact is closed. contact is closed. Alternative modes: ”Isochronous” or ”Droop value” Alternative engine revolutions: 1500 rpm or 1800 Preset mode: ”Isochronous” rpm. Preset rpm: dependent on the specification ordered. PTO regulator gradient is used The gradient is defined either by a droop value in per- Maximum engine revolutions (CIU) cent if the Regulator roop value parameter is equal to Potentiometer signal voltage on the CIU unit corre- zero or Nm/rpm if the Regulator gradient parameter is sponding to nominal revolutions (1500/1800 rpm) plus equal to zero. (+) 120 rpm. Min. value: 1.90 V Regulator droop value Preset value: 4.50 V Selects the droop value magnitude to be used when Max. value: 4.70 V droop value is activated (percent). Min. value: 0 % Pre-heating for ignition Preset value: 4 % Selects whether pre-heating and post heating is to be Max. value: 8 % activated directly when the ignition is turned on. The pre-heating and post heating periods are depend- Stop function ent on coolant temperature. The CIU unit stop signal is energized during “opera- If the parameter is in ”Off” mode, pre-heating and post tions” or “stop”. heating must be activated manually via the ignition Preset mode: ”Stop” lock or pre-heater button. Alternative modes: “Off” or “On” Lamp test Preset mode: “Off” This parameter determines if a lamp test is to be per- formed when the system is started. Alternative modes: “Off” or “On” Preset mode: “On” Idling speed Setting idle revolutions. Min. value: 600 rpm Preset value: 900 rpm Max. value: 1200 rpm 72 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting Adjustable parameters TAD1640VE-B, TAD1641VE, TAD1641VE-B, TAD1642VE, TAD1642VE-B, TAD1643VE, TAD1650VE, TAD1660VE, TAD1661VE, TAD1662VE NOTICE! Some parameters require special authoriza- tion. Inverted regulator mode Idling speed Select if droop value is to be active. Setting idle revolutions. Alternative modes: “No droop value” or “Variable Min. value: 550 rpm droop value” Preset value: 600 rpm Preset mode: “Fixed droop value” Max. value: 800 rpm TAD1650VE: 700 rpm Regulator mode Select if droop value is active. Idle voltage (CIU) Alternative modes: “Off” or “No” Throttle control input signal voltage to corresponding Preset mode: ”No” idle at the CIU unit. Min. value: 0.30 V Primary regulator mode Preset value: 1.17 V Selects the regulator to be used when the regulator Max. value: 1.90 V contact is closed. Alternative modes: ”Isochronous” or ”Droop value” Voltage max. rpm (CIU) Preset mode: ”Isochronous” Throttle control input signal voltage to corresponding full throttle at the CIU unit. Regulator gradient Min. value: 1.90 V Determines the droop value to be used (gradient) Preset value: 4.50 V Min. value: 10 Nm/revolution Max. value: 4.70 V Preset value: 25 Nm/revolution Max. value: 128 Nm/revolution Pre-heating for ignition Selects if pre-heating is to be activated directly the Stop function ignition is turned on. If the parameter is in ”Off” mode, Preset mode: ”Stop” pre-heating and post heating must be activated man- ually via the ignition lock or pre-heater button. CIU stop function Alternative modes: “Off” or “On” The CIU unit stop signal is energized during “Opera- Preset mode: “Off” tions” or “Stop”. Preset mode: ”Stop” Lamp test This parameter determines if a lamp test is to be per- formed when the system is started. Alternative modes: “Off” or “On” Preset mode: “On” 47701683 10-2012 © AB VOLVO PENTA 73 Calibration and Settings, Parameter Setting Adjustment of speed regulator TAD1640GE, TAD1641GE, TAD1642GE, TAD1650GE, TAD1651GE, TWD1643GE NOTICE! The regulator has a basic factory setting that is optimized to suit the most common generator set applications. Use the VODIA tool (including EMS soft- ware), to read and adjust the P, I and D sections of the engine speed regulator. The adjustment is made to give more stable and even running of the engine and to adapt the engine to the specific generator set appli- cation. PID = Proportional, Integrating, Differentiating A = rpm B = time 1 = Demanded engine speed 2 = True engine speed A P-value 1 Amplifier (Gain), amplification of the difference between the actual value and the set value. A reduced value (Fig.1) gives a weaker responce to speed deviations. Reduce the P-value to reduce oscil- 2 lations arising from large differences in speed/load application. B Fig. 1 Fig 1 P0016983 P-value too low A 1 An increased value (Fig 2) gives a shorter response time. Increase the P-value for faster compensation of large differences in speed/load. 2 Fig 2 B P-value too high Fig. 2 P0016984 74 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting I-value A Stabilizes (stability), reacts to the time of the speed 1 deviation. A reduced value (Fig.3) increases the time taken by the system to respond after a load change. Reduce the I-value to reduce the oscillations that arise with slowly increasing loading. 2 B Fig 3 Fig. 3 I-value too low P0016985 A 1 An increased value (Fig 4) gives a shorter response time. Increase the I-value to provide better load response for slowly increasing loads. 2 Fig 4 B I-value too high or D-value too low Fig. 4 P0016986 D-value Compensates (derivative). Reacts to fast changes of engine speed/load. A-reduced value (Fig 4) gives a greater sensivity to A fast changes of engine speed/load. Reduce the D- value ro reduce oscillations caused by fast changes. 1 An increased value (Fig 5) gives a reduced sensi- tivity to fast load changes. increase the D-value to provide a better ability to compensate for fast changes. 2 B Fig 5 Fig. 5 D-value too high P0016987 47701683 10-2012 © AB VOLVO PENTA 75 Calibration and Settings, Parameter Setting Alarm limits TAD1640GE, TAD1641GE, TAD1642GE, TAD1650GE, TAD1651GE, TWD1643GE Alarm threshold, high oil temperature Overspeed limit A warning lamp is lit at this temperature. Percent above normal revolutions at which the over- Min. value: 120 °C (248 °F) speed warning is activated. Preset value: 125 °C (257 °F) Min. value: 0 % Max. value: 130 °C (266 °F) Preset value: 20 % Max. value: 20 % Alarm threshold, high coolant temperature A warning lamp is lit at this temperature. Min. value: 95 °C (203 °F) Preset value: 98 °C (208 °F) Max. value: 103 °C (217 °F) Alarm limits TAD1640GE, TAD1640VE-B, TAD1641GE, TAD1641VE, TAD1641VE-B, TAD1642GE, TAD1642VE, TAD1642VE-B, TAD1643VE Alarm threshold, high oil temperature Alarm threshold, high coolant temperature A warning lamp is lit at this temperature. A warning lamp is lit at this temperature. Min. value: 120 °C (248 °F) Min. value: 95 °C (203 °F) Preset value: 125 °C (257 °F) Preset value: 98 °C (208 °F) Max. value: 130 °C (266 °F) Max. value: 103 °C (217 °F) Alarm limits TAD1640VE-B, TAD1641VE, TAD1641VE-B, TAD1642VE, TAD1642VE-B, TAD1643VE, TAD1650GE, TAD1650VE, TAD1651GE, TAD1660VE, TAD1661VE, TAD1662VE, TWD1643GE Alarm threshold, high oil temperature Alarm threshold, high coolant temperature A warning lamp is lit at this temperature. A warning lamp is lit at this temperature. Min value: 120 °C (248 °F) Min value: 95 °C (203 °F) Preset value: 125 °C (257 °F) Preset value: 98 °C (208 °F) Max value: 130 °C (266 °F) Max value: 107 °C (217 °F) 76 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting Engine protection TAD1640GE, TAD1641GE, TAD1642GE, TAD1650GE, TAD1651GE, TWD1643GE Oil temperature Oil pressure Determines whether engine protection is to be acti- Determines whether engine protection is to be acti- vated in respect of high oil temperature. A fault code vated in respect of low oil pressure. A fault code is is registered and the engine is shut down. registered and the engine is shut down. Alternative modes: “Yes” or “No” Alternative modes: “Yes” or “No” Preset mode: “Yes” Preset mode: “Yes” Coolant temperature Piston cooling pressure Determines whether engine protection is to be acti- Determines whether engine protection is to be acti- vated in respect of high coolant temperature. A fault vated in respect of low piston cooling pressure. A fault code is registered and the engine is shut down. code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Alternative modes: “Yes” or “No” Preset mode: “Yes” Preset mode: “Yes” Coolant level Crankcase pressure Determines whether engine protection is to be acti- Determines whether engine protection is to be acti- vated in respect of low coolant level. A fault code is vated in respect of high crankcase pressure. A fault registered and the engine is shut down. code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Alternative modes: “Yes” or “No” Preset mode: “Yes” Preset mode: “Yes” Charge air temperature Overspeed warning shutdown Determines whether engine protection is to be acti- Determines whether engine protection is to be acti- vated in respect of high charge air temperature. A fault vated in respect of overspeed. A fault code is regis- code is registered and the engine is shut down. tered and the engine is shut down. Alternative modes: “Yes” or “No” Alternative modes: “Yes” or “No” Preset mode: “Yes” Preset mode: “Yes” Charge pressure Exhaust temperature (only TWD1643GE) Determines whether engine protection is to be acti- Determines whether engine protection is to be acti- vated in respect of high charge air pressure. A fault vated in respect of high exhaust temperature. A fault code is registered and the engine is shut down. code is registered and the engine is shut down. Alternative modes: “Yes” or “No” Alternative modes: “Yes” or “No” Preset mode: “Yes” Preset mode: “Yes” 47701683 10-2012 © AB VOLVO PENTA 77 Calibration and Settings, Parameter Setting Engine protection TAD1640VE-B, TAD1641VE, TAD1641VE-B, TAD1642VE, TAD1642VE-B, TAD1643VE, TAD1650VE, TAD1660VE, TAD1661VE, TAD1662VE Oil temperature Oil pressure Determines whether engine protection is to be acti- Determines whether engine protection is to be acti- vated in respect of high oil temperature. A fault code vated in respect of low oil pressure. A fault code is is registered and the engine is shut down. registered and the engine is shut down. TAD1650VE: a fault code is registered and an orange Alternative modes: “Yes” or “No” or red warning lamp is lit. Preset mode: “Yes” Alternative modes: “Yes” or “No” Preset mode: “Yes” Piston cooling pressure Determines whether engine protection is to be acti- Coolant temperature vated in respect of low piston cooling pressure. A fault Determines whether engine protection is to be acti- code is registered and the engine is shut down. vated in respect of high coolant temperature. A fault Alternative modes: “Yes” or “No” code is registered and the engine is shut down. Preset mode: “Yes” Alternative modes: “Yes” or “No” Preset mode: “Yes” Crankcase pressure Determines whether engine protection is to be acti- Coolant level vated in respect of high crankcase pressure. A fault Determines whether engine protection is to be acti- code is registered and the engine is shut down. vated in respect of low coolant level. A fault code is Alternative modes: “Yes” or “No” registered and the engine is shut down. Preset mode: “Yes” TAD1650VE: a fault code is registered and an orange warning lamp is lit. ECU temperature (only TAD1650VE) Alternative modes: “Yes” or “No” Determines whether engine protection is to be acti- Preset mode: “Yes” vated in respect of high control unit temperature. A fault code is registered and an orange or red warning Charge air temperature lamp is lit. Determines whether engine protection is to be acti- vated 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” Charge pressure Determines whether engine protection is to be acti- vated 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” 78 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting CAN bus settings Background With new emission legislations the requirements on customer panels increases and a document describing what needs to be implemented in the OEM CAN panels is needed. Requirements on OEM panels There is one message that has to be sent to the VP EECU and that is the VP status message. See section VP STATUS MESSAGE: OC FF 46 11. Without this message the EECU will set a fault code on the CAN bus and disregard more communication. Engine interface connector (EIC) The EIC contains 8 pins with the following functions: 1 CAN High 2 CAN Low 3 Battery minus 4 Battery plus 5 Battery after key 6 Extra stop 7 J1587A 8 J1587B This is where any CAN panel shall connect to battery plus and battery minus in order to be powered. Battery after key and extra stop shall get the positive voltage from pin 4 (battery plus) when powered. 47701683 10-2012 © AB VOLVO PENTA 79 Calibration and Settings, Parameter Setting Battery after key - signal The battery after key - signal is a “wake up” signal to the EMS. When this pin get powered the main relay will be activated which will power the EMS and the EMS will start to communicate. This pin should have power for as long as the EMS is supposed to communicate. The EMS will hold this relay even without getting power via this signal once the software is up and running. However, in order to avoid problems in the aftermarket, it shall always be power on this pin when the EMS is supposed to com- municate. NOTICE! The battery after key signal can be config- ured via VP aftermarket tool. So that the engine will stop if power is removed from the pin. (Pin 5 in the 8- pole Engine Interface Connector; EIC). It shall also always be possible to power this pin with- out having to start the engine in order to be able to work on the engine with after market tools. 80 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting Battery plus and minus The battery plus and minus in the EIC is connected to the battery via the starter motor. I.e. these pins in the EIC are outputs that are intended to power other CAN nodes connected to the engine CAN network. Failure to do this can cause EECU damages. Power down When the EMS should be deactivated the power on battery after key should be removed and a stop signal should be sent. This will let the EMS save the data it needs to save and perform a controlled power down. The VP status message should be sent until the EMS stops to communicate in order to avoid unnecessary error codes. NOTICE! The stop signal can be either the available CAN stop or the extra stop in the EIC or with the ignition key. In both cases the stop signal should only be active for a limited period of time. 47701683 10-2012 © AB VOLVO PENTA 81 Calibration and Settings, Parameter Setting VP STATUS MESSAGE: OC FF 46 11 The VP status message is a VP proprietary J1939 message that the engine always needs to receive for as long as it is awake. All necessary engine function- ality can be controlled via this message. ID: 0C FF 46 11 Byte: 1 bits 8-7 Idle speed select bits 6-5 Governor mode request bit 4-3 Stop request bit 2-1 Start request Byte: 2 bits 8-7 Engine protection override bits 6-5 Preheat request bit 4-3 Diagnosis request bit 2-1 Frequency select Byte: 3 all bits Accelerator pedal position Byte: 4 all bits Accelerator pedal positon Byte: 5 bits 2-1 Fuel disable request Table1: The contents of the VP status message. Power up The EECU needs to receive the VP status message within 500ms of power up. If this message is not sent the EMS will set an error code on the CAN bus com- munication. It is recommended that the OEM CAN panel always send this message when it is powered and that the panel also controls when the engine should be ignited. See battery after key - signal for more information regarding the ignition function. 82 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting Stop functionality There are several ways of stopping a VP engine and one or two of the following shall be used: 1 Stop request via VP status on CAN. 2 Extra stop signal in EIC. (Engine Interface Control) 3 TAD1660: Ignition Off None of these stop signal should be continuously active when the engine is standing still with power to the EMS. Sending a continuously active stop signal with ignition on could damage the EMS. See VP status message for more information about how to send the CAN stop request. Engine Speed ERR StopRequest_vPStatus 0 Active Stop signal active < 0,5s Inactive P0013957 Figure 2: An example on stopping an engine with a short active stop signal. 47701683 10-2012 © AB VOLVO PENTA 83 Calibration and Settings, Parameter Setting Start functionallety There are two ways to start the engine and they are: 1 Sending a start request via the VP status message on CAN. 2 Having the EMS powered and turn the engine. For more information regarding the start request func- tion see VP status message. There are four things that will stop the engine from cranking: 1 The start request signal is deactivated. 2 There is a stop signal activated. 3 The engine rpm is high (this means that the engine has started) 4 The cranking time has been to long (The EMS will protect the starter from overheating by not allowing to crank to long). ERR StartRequest_vPStatus 0 Start request activated Active Starter motor turning engine Start cranking Engine accelerates Inactive P0013958 Figure 3: A succesfull start attempt. 84 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting Accelerator Pedal Position The accelerator pedal position part of the VP status message is two bytes long and the range is 0 - 100%. For VE engines 0% means idle speed and 100% means maximum available speed at the current engine load. If a mobile VE engine does not receive any speed request it will got to idle speed. For GE engines 0% means nominal speed -120 rpm and 100% means nominal speed +120 rpm. In order to request the engine to run at nominal speed (1500 or 1800 rpm) the pedal position needs to be set to 50%. If a GE engine does not receive any speed request it will stay at the last requested speed. Message Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 VP70_VP_Status 00 00 FF 01 00 00 00 00 Table 2: An example of the VP status message In the table above there is an example of how the VP status message can be sent. The pedal position part is byte 3 and 4 and byte 4 is the most significant byte which means that in this case the pedal position is 0x01FF. Sins the resolution of this signal is 100/1023% / Bit, the pedal position in percent is calculated as follows: Pedal position = 511 x (100/1023) ≈50% 47701683 10-2012 © AB VOLVO PENTA 85 Calibration and Settings, Parameter Setting Error code presentation VP engines uses standard J1939 frames for sending error codes. VP EMS engines uses conversion method 4 when sending error codes on the CAN bus. The CAN panels always have to display SPN and FMI numbers on any active error code. It can be completed with a generic name for the error code but the SPN and FMI must also be displayed. Single active error code For single active error codes the DM (Active Diagnostic Trouble Codes) is used. Table 3 shows how a DM1 signal from an EMS engine is sent. DM1 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 18FECA00x 04 FF 64 00 12 01 FF FF Table 3: Example on how an EMS engine sends the error codes. Byte Value (Hex) Value (Dec) Description 1 0x04 4 Byte 1 includes lamp colour and 4 corresponds do “yellow” lamp. 2 0xFF 255 Not used. 3 0x64 100 First and least significant byte of SPN. 4 0x00 0 Second byte of SPN. 5 0x12 18 Bits 6-8 are the most significant bits of SPN. Bits 1-5 are the FMI value. 6 0x01 1 Bit 8 is the SPN conversion method. Bits 1-7 are the occurrence coun- ter. 7 0xFF 255 Not used 8 0xFF 255 Not used Table 4: How to interpret the VP DM1 message. 86 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting Multiple active error codes If there are multiple simultaneously active error codes the broadcast announce (TP.CM_BAM) and the data transfer messages (TP.DT) are used in order to send all error codes. The CAN panel shall be able to display up to 10 simul- taneously active error codes. All of them do not need to be displayed at the same time but it shall be possible to scroll through them. NOTICE! When the CAN diagnostics uses the trans- port protocol, the standard polling is not supported, meaning that no “request to send” is transmitted and no “clear to send” is being received. No “end of mes- sage ack” is received. The EMS will send a BAM and directly there after follow by DM1 / DM2. Engine protection functionality VP engines are designed to protect themselves from being damaged by e.g. overheating or low oil pressure and will take action in order to avoid engine damage. No action should be taken by the CAN panel to stop the engine in case an engine protection error is sent. NOTICE! The engine protects itself from being dam- aged but it does not consider the surrounding it is installed in. 47701683 10-2012 © AB VOLVO PENTA 87 Calibration and Settings, Parameter Setting More available control functions There are other possibilities than the VP status/pedal position message in order to control the engine speed. Torque speed control - TSC1 (0C 00 00 03/11/E6) The TSC1 message has priority over the pedal position that is sent with the VP status message. With the TSC1 message with source address 0x03, 0x11, 0xE6, the engine speed and torque can be continuously control- led. With the TSC1 message with the source address 0x11 it is possible to limit the available torque or speed from the engine. Torque Limit 2000 1800 1600 1400 1200 Nm 1000 800 600 400 200 0 750 950 1150 1350 1550 1750 1950 P0013959 rpm Figure 4: The yellow graph shows the available engine torque when the TSC1 signal sets to 80% in the torque limiting factor. The picture shows an example on how an engine would react when limiting the torque via the TSC1 message. Start battery test Whit the fuel disable request in the VP status message, it is possible to perform a start battery test. 88 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting Special requirements with EATS The engines equipped with exhaust after treatment systems have some more requirements regarding which messages that includes error code information. DEF level The DEF level is broadcasted on the J1939 bus via SPN 1761. SPN 1761 will show a value between 0 - 100% DEF level diagnostics The DEF level diagnostics are sent via two different SPN numbers. These SPN numbers are SPN 5245 and 5246 and they are included in the message AT1TI (PGN 65110). See table 5 for location of these signals in AT1TI. SPN Start byte Start bit Length (bits) 5245 5 6 3 5246 6 6 3 Table 5: SPN 5245 and 5246 in PGN 65110 (AT1Ti). If the DEF level is low SPN 5245 will be sent with a value that shows how severe the low level is as descri- bed in table 6. SPN 5245 Value Severity Level 1 DEF/AdBlue level low. Solid signal. 4 DEF/AdBlue level empty. Flashing with 1Hz. Table 6: SPN 5245 and 5246 in PGN 65110 (AT1Ti). There are different inducement levels to motivate the operator to not use the engine when the EATS does not work properly. The inducement level active is com- municated via SPN 5246 as described in table 7. SPN 5246 Value Inducement Level 3 Engine derate 4 Pre severe inducement 5 Severe inducement 6 Temporary override of inducement Table 7: SPN 5245 and 5246 in PGN 65110 (AT1Ti). DEF symbol If a symbol is used in the display for any SCR related SPN, the symbol shown in figure 5 has to be used. P0013960 47701683 10-2012 © AB VOLVO PENTA 89 Calibration and Settings, Parameter Setting Figure 5: The symbol used for DEF functions. Stop functionality The stop function in EMS2 works in two different ways if stop function is set to “energized to run”, described as follows, (picture). ETR stands for Energized To Run, and ETS stands for Energized To Stop EMS 2 EMS 2.2 (Tier 4) Engine: 164X/165X Engine 1660/164X VE-B 1 1 2 2 3 3 Battery 4 Battery 4 switch 5 switch 5 Stop 6 ETR / ETS Stop 6 ETR / ETS 7 7 8 8 Fig. 5 P0016988 90 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Parameter Setting EMS-2 extra stop On EMS2 engines the extra stop is level triggered as shown in figure 7. The default setting is “Energized to stop” which means that when there is power on this pin the engine will stop and it will not be able to start until the stop signal is deactivated. If the parameter “Stop function EMS, energized to” is set to run, there needs to be battery power on this pin in order for the engine to be able to run. Running Engine Running Stopped Battery + Energized to stop Open Circut No stop STOP! Battery + Energized to run Open Circuit P0013962 Figure 7: The extra stop functionallety on EMS2 engines. Never have a stop signal being continuously sent to a powered control unit. If there is a continuous active stop signal over time, it could damage the engine con- trol unit. Figure 1 shows that the stop signal should be sent as a pulse signal. The voltage to the stop signal should come from pin 4 in the engine interface connector. 47701683 10-2012 © AB VOLVO PENTA 91 Calibration and Settings, Diagnostic Function Diagnostic Function The diagnostic function monitors and controls that the EMS system functions normally. The diagnostic func- tion has the following tasks: • Detecting and locating disturbances • Reporting detection of disturbances • Providing guidance when fault tracing NOTICE! With the DCU:n it is possible choose the lan- guage that the information is presented in. If the diagnostic function detects a disturbance in the system, this is reported using fault codes via the instru- ments. Both active (unrectified) and passive (rectified) faults are stored in the control unit. Refer to the “Operation” heading for reading fault codes/fault messages. All fault codes and fault messages are found in the fault code list, with information about the reason, reaction and measures to be taken. Refer to Fault Code Reg- ister. NOTICE! All instruments are optional. Effect on engine Engines are affected differently, depending on the severity of the fault discovered by the diagnostic func- tion. A fault message in the form of a fault code is always generated when a malfunction is discovered by the diagnostic function. Engines are affected differently, depending on the severity of the fault: • The engine is not affected • Engine goes to idle • Engine torque is restricted to a certain amount • Engine is stopped 92 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Diagnostic Function Active and Inactive Faults Active faults Inactive faults At the same time, the fault is stored in the control unit • DCU – the fault is indicated as passive memory. When the fault has been attended to and the ignition is switched off and on again, the fault disap- • CIU – the diagnostic lamp goes out pears as active. • DU – the fault message disappears (inactive DCU (Display Control Unit) faults cannot be read out) • text !! ENGINE WARNING !! shown on the dis- • “Easy Link” – the lamp on the alarm panel goes play. out CIU (Control Interface Unit) • the diagnostic lamp starts to flash. • ”Easy Link” instrument - the relevant lamp on the alarm panel lights up - after the diagnostic button has been pressed, the fault code is shown as text on the tachometer display. DU (Display Unit) • Either WARNING! or ALARM STOP (a buzzer sounds) will be shown on the display, depending on the severity of the fault. • Fault codes can also be read off using the VODIA tool. For instructions, see “VODIA User’s Guide”. Operation When a malfunction has occurred and the diagnostic Reading fault codes via the DU (Display Unit) system has generated one or more fault codes, these Depending on the severity of the fault the text, either are read out differently depending on the equipment WARNING! or ALARM STOP (a buzzer sounds) will used. Please refer to “Fault code messages”. be shown on the display If the system indicates that a fault code has been 1 Press any button to come to the fault list. The set: fault list shows operation hours and fault mes- 1 Cut engine speed to idle, or shut the engine off. sage. 2 For DCU/DU 2 Look up the fault code in Fault Code Register Read the fault code from the display, please and take the recommended measures. refer to Reading fault codes via the DCU or 3 Press on ACK to acknowledge the fault code. Reading fault codes via the DU. The display background will change color (the For CIU buzzer stops sounding). press the diagnostic button and read the fault code, by observing the flashing of the diagnostic 4 Press on EXIT to leave the fault list. lamp. Refer to Reading fault codes via the diagnostic lamp, CIU. 3 Look up the fault code in the Fault Code Regis- ter chapter and take the recommended meas- ures. 47701683 10-2012 © AB VOLVO PENTA 93 Calibration and Settings, Diagnostic Function Reading fault causes via the DCU (Display Control Reading fault codes via an “Easylink” instrument Unit) When the system has discovered a malfunction, this When a fault code is set, the following text is shown is reported by the diagnostic lamp which starts to on the display: flash. !! ENGINE WARNING !! 1 Press the diagnostic button. The fault code is alternated withPress SEL for information. shown as text on the tachometer display. Read the fault code as follows: 2 Look up the fault code in the Fault Code Regis- 1 Press SEL-button to come to the fault list. ter chapter and take the recommended meas- The fault list shows: ures. -Operation hours -Fault message 3 When the fault has been rectified, the fault code -Active/inactive disappears from the display and the diagnostic lamp goes out. 2 Look up the fault code in theFault Code Regis- ter chapter and take the recommended meas- ures. 3 Press ESC-button to leave the fault list. NOTICE! To enter the fault list when no fault code has been set, press the SEL button and select Diagnos- tics from the menu. Reading fault codes via the diagnostic lamp on Erasing fault codes the instrument panel, CIU Fault codes must be erased by an authorized Volvo When the system has discovered a malfunction, the Penta workshop by means of the VODIA tool. diagnostic lamp starts to flash. If the diagnostic button is depressed and then released, a fault code is flashed out. The fault code consists of two groups of flashes, sep- arated by a pause of two seconds. A fault code is obtained by counting the number of flashes in each group Example: paus = Fault Code 2.4 The fault code is stored and can be read as long as the malfunction remains. You can find information about cause, reaction and actions in the Fault Code Register chapter. Read the fault code as follows: 1 Press the diagnostic button. 2 Release the diagnostic button and make a note of the fault that is flashed out. 3 Repeat items 1-2. A new fault code is flashed ou tif more are stored. Repeat until the first fault code is repeated. NOTICE! When the first fault code reoccurs, all the fault codes have been read. If the diagnostics button is depressed after the fault has been corrected and the fault code deleted, the code 1.1, No fault, will be shown. 94 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Fault Code Register Fault Code Register CAUTION! Read through the safety advice before starting any work. The fault codes below comprise: - a fault text message displayed when a DCU or DU is installed. - a flash code, e.g. 5.4, read off from the diagnostics lamp; refer to Calibration and Settings page 92 - 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 37. No fault (Code 1.1) Cause Reaction Remedy There are no active faults. Exhaust Temperature (Code 1.9, PID 173/SPN 1184) Cause Reaction Remedy • Exhaust temperature to high • Warning lamp lights up • Insufficient air supply • Engine is shutdown • Low coolant level • Air in the coolant system • Faulty circulation pump • Blocked charge air cooler • High temperature, charge air- cooler • High back pressure in the exhaust system • Check wastegate function Water in Fuel (Code 2.1, PID/SPN 97) Cause Reaction Remedy • Water in fuel • None • Empty the primary fuel filter Coolant Level (Code 2.2, PID/SPN 111) Cause Reaction Remedy • Low coolant level • Engine control module • Check the coolant level reduces engine power • Check coolant level monitor (unless the protection has function been shut off with the VODIA diagnostic tool) Coolant Level Sensor (Code 2.3, PID/SPN 111) Cause Reaction Remedy • Short circuit to positive (+) • None • Check that the coolant level sensor cable is not damaged • Fault in sensor • Check coolant level sensor function 47701683 10-2012 © AB VOLVO PENTA 95 Calibration and Settings, Fault Code Register Flywheel Speed Sensor (Code 2.4, SID 22/SPN 637) Cause Reaction Remedy • No signal • Engine is very difficult to start • Check that the sensor con- and runs roughly when it nector is correctly installed • Abnormal frequency starts • Check that the engine speed • “Intermittent” signal from the sensor cable is not damaged sensor • Check that the engine speed • Fault in sensor sensor is correctly installed in the flywheel housing • Check engine speed sensor function Camshaft Drive Speed Sensor (Code 2.5, SID21/SPN 636) Cause Reaction Remedy • No signal • Engine takes longer to start • Check that the engine speed than normal. Engine runs nor- sensor connector is correctly • Abnormal frequency mally when running installed • Fault in sensor • Check that the engine speed sensor cable is not damaged • Check that the engine speed sensor is correctly installed in the upper timing gear cover. • Check engine speed sensor function. Engine Speed (Code 2.6, PID/SPN 190) Cause Reaction Remedy • Engine speed too high • None • 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 Reaction Remedy • Shorted to plus (+) or minus • Engine goes to idle • Check that the potentiometer (-) has been connected correctly • Speed feezes • Fault in sensor • Check that the cable harness to the potentiometer has not been damaged • Check the potentiometer function Indicator for Water in Fuel (Code 2.9, PID/SPN 97) Cause Reaction Remedy • Short circuit • None • Check the indicator cables for breaks and short circuits • Open circuit • Check indicator function. • Fault in indicator Change indicator as neces- sary 96 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Fault Code Register Oil Pressure Sensor (Code 3.1, PID/SPN 100) Cause Reaction Remedy • Short circuit to positive (+) or • None • Check that the oil pressure earth (ground) (–) sensor cable is not damaged • Open circuit • Check that the oil pressure sensor is correctly connected Boost Temperature Sensor (Code 3.2, PID/SPN 105) Cause Reaction Remedy • Short circuit to positive (+) or • None • Check that the boost temper- earth (ground) (–) ature sensor connector is cor- rectly installed • Open circuit • Check that the boost temper- ature sensor cable is not dam- aged • Check that the boost temper- ature sensor is correctly installed • Check boost temperature sensor function Coolant Temperature Sensor (Code 3.3, PID/SPN 110) Cause Reaction Remedy • Short circuit to positive (+) or • Preheating is also activated • Check that the coolant tem- earth (ground) (–) when the engine is hot perature sensor connector is correctly installed • Open circuit • Check that the coolant tem- perature sensor cable is not damaged • Check that the coolant tem- perature sensor is correctly installed • Check coolant temperature sensor function Boost Pressure Sensor (Code 3.4, PID/SPN 102/106) Cause Reaction Remedy • Short circuit to positive (+) or • Engine smokes more than • Check that the boost pressure earth (ground) (–) normally during acceleration/ sensor connector is correctly load increase installed • Open circuit • Check that the boost pressure sensor cable is not damaged • Check that the boost pressure sensor is correctly installed • Check boost pressure sensor function 47701683 10-2012 © AB VOLVO PENTA 97 Calibration and Settings, Fault Code Register Boost Pressure Sensor (Code 3.5, PID/SPN 106) Cause Reaction Action • High charge pressure • Engine power is reduced or • Check that the charge air engine stops. pressure sensor connector is correctly installed • Check that the charge air pressure sensor cable is not damaged • Check that the charge air pressure sensor is correctly installed • Check charge air temperature sensor function Fuel Pressure Sensor (Code 3.6, PID/SPN 94) Cause Reaction Remedy • Short circuit to positive (+) or • None • Check that the fuel pressure earth (ground) (–). sensor connector is correctly installed. • Open circuit. • Check that the fuel pressure sensor cable is not damaged. • Check that the fuel pressure sensor is correctly installed. • Check fuel pressure sensor function. Oil Temperature Sensor (Code 3.7, PID/SPN 175) Cause Reaction Remedy • Shorted to plus (+) or minus • None • Check that the cable harness (-) to the oil temperature sensor has not been damaged • Break • Check that the oil tempera- ture sensor has been con- nected correctly Fuel Pressure (Code 3.8, PID/SPN 94) Cause Reaction Remedy • Low supply pressure • None • Check if it is possible to build up pressure with the hand pump • Check the fuel filter • Check the fuel pre-filter Battery Voltage, EMS (Code 3.9, PID/SPN 158) Cause Reaction Remedy • Faulty alternator • None • Check the supply voltage from the control unit • Faulty battery, battery cables 98 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Fault Code Register Start output/Start motor relay (Code 4.6, PPID 3/ SPN 677) Cause Reaction Remedy • Shorted to plus (+) or minus • The engine cannot be started • Check that connections to the (-) ignition key/start panel have • The engine starts immedi- not been damaged • Activated for too long ately when ignition is turned on • Check that the cable harness to the ignition key/sart panel has not been damaged Stop Input EMS (Code 4.8, PPID 6/SPN 970) Cause Reaction Remedy • Short circuit to negative (-) • Engine can only be stopped • Check that the starter switch with the auxiliarystop connections are not damaged • Open circuit TWD1643GE Exhaust Temperature (Code 4.9, PID 173/SPN 1184) Cause Reaction Remedy • Short circuit to positive (+) or • Warning lamp lights up • Check that the exhaust tem- negative (-) perature sensor connector is • Engine control unit limits properly mounted • Open circuit engine power • Check that the wiring to the • Exhaust temperature to high exhaust temperature sensor is not damaged • Check that the exhaust tem- perature sensor is correctly mounted • Check the exhaust tempera- ture sensor function Starter Input CIU (Code 5.2, PPID 4/SPN 520194) Cause Reaction Remedy • Shorted to minus (-) • The engine cannot be started • Check that connections to the ignition key/start panel have • Activated for too long • The engine starts immedi- not been damaged ately when ignition is turned on • Check that the cable harness to the ignition key/start panel has not been damaged Stop Input CIU (Code 5.3, PPID 6/SPN 52095) Cause Reaction Remedy • Short circuit to negative (-) • Engine can only be stopped • Check that the starter switch with the auxiliary stop (AUX connections are not damaged • Open circuit STOP) on engine • Check that the ignition switch • Activated for too long time • Engine stops. A fault code is cable is not damaged displayed for 40 seconds and the engine can not be started during this time. When a fault code is active, the engine can be started but not stopped 47701683 10-2012 © AB VOLVO PENTA 99 Calibration and Settings, Fault Code Register Preheating Relay (Code 5.4, PID 45/SPN 626) Cause Reaction Remedy • Short circuit to positive (+) or • Preheating can not be acti- • Check that the relay input earth (ground) (–). vated. cable is not damaged. • Open circuit. • Preheating is constantly con- • Check relay function. nected. Air Filter Pressure (Code 5.5, PID/SPN 107) Cause Reaction Remedy • Too large pressure drop • Less good response from • Check the air filter across filter engine Air Filter Sensor (Code 5.6, PID/SPN 107) Cause Reaction Remedy • Shorted to plus (+) or minus • None • Check that the air filter sensor (-) contact is correctly installed • Break • Check that the cable harness to air filter sensor has not been damaged • Check the air filter sensor functionality Oil Level (Code 5.7, PID/SPN 98) Cause Reaction Remedy • Oil level to low • None • Check the oil level Oil Temperature (Code 5.8, PID/SPN 175) Cause Reaction Remedy • Oil temperature is too high • The engine control module • Check the oil level limits engine output(unless • Check the oil temperature protection has been turned off with thediagnosis tool • Check the oil temperature VODIA) sensor function Oil Level Sensor (Code 5.9, PID/SPN 98) Cause Reaction Remedy • Shorted to plus (+) or minus • None • Check that the cable harness (-) to the oil level sensor has not been damaged • Break • Check the oil level sensor function 100 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Fault Code Register Coolant Temperature (Code 6.1, PID/SPN 110) Cause Reaction Remedy • Coolant temperature is too • Engine control module • Check the coolant level high reduces engine power • Check the charge air cooler (unless the protection has (cleanliness) been shut off with the VODIA diagnostic tool) • Check if there is air in the cooling system • Check the pressure cap on the expansion tank • Check coolant temperature sensor function • Check thermostat function Boost Temperature (Code 6.2, PID/SPN 105) Cause Reaction Remedy • Boost temperature is too high • Engine control module • Check the coolant level reduces engine power • Check the charge air cooler (unless the protection has (cleanliness) been shut off with the VODIA diagnostic tool) • Check boost temperature sensor function • Check the function of the ther- mostat Data Link (CAN), CIU (Code 6.4, SID 231/SPN 639) Cause Reaction Remedy • Faulty data link (CAN), , CIU • Instruments and warning • Check that the 8-pin connec- lamps stop working tor is not damaged • Check that the cables between the CIU and the engine management unit are not damaged Data Link (CAN), EMS 2 (Code 6.5, SID 231/SPN 639/2017/PSID 201) Cause Reaction Remedy • Internal fault in control mod- • Engine not operating: engine • Check that the 8-pin connec- ule can not be started. Engine tor is not damaged operating: engine idles and • Check that the cables can only be stopped with the between the CIU and the auxiliary stop (AUX-stop) engine management unit are not damaged • Check that sleeves 11 and 12 in the connector on the CIU are not damaged 47701683 10-2012 © AB VOLVO PENTA 101 Calibration and Settings, Fault Code Register Oil Pressure (Code 6.6, PID/SPN 100) Cause Reaction Remedy • Oil pressure is too low • Engine control module • Check oil level reduces engine power • Check that the air filter is not (unless the protection has blocked been shut off with the VODIA diagnostic tool) • Check system pressure valves and safety valves in the oil system • Check oil pressure sensor function Piston Cooling Pressure (Code 6.7, PPID 8/SPN 520192) Cause Reaction Remedy • Piston cooling pressure is too • Engine stopped • Check that the oil pressure in low the engine exceeds175 kPa (25.4 psi) Piston Cooling Pressure Sensor (Code 6.8, PPID 8/SPN 520192) Cause Reaction Remedy • Shorted to plus (+) or minus • None • Check that the piston cooling (-) pressure sensor contact is correctly installed • Break • Check that the cable harness to the piston cooling pressure sensor has not been dam- aged • Check the piston cooling pressure sensor functionality Battery Voltage, CIU (Code 6.9, PID/SPN 158) Cause Reaction Remedy • Short circuit to negative (-) • Problems in engine starting • Check the supply voltage from the control unit • Faulty alternator • Check the batteries • Faulty battery, battery cables • Check the alternator • Check the 8-pin contact Injector, Cylinder #1 (Code 7.1, SID 1/SPN 651) Cause Reaction Remedy • Electrical fault • Engine runs on 5 cylinders • Check that the injector cables are not damaged • Faulty compression or injec- • Abnormal sound tor • Check that the injector con- • Reduced performance nections are not damaged • Check fuel supply pressure • Check the valve clearance • Do a compression test and check cylinder #1 102 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Fault Code Register Injector, Cylinder #2 (Code 7.2, SID 2/SPN 652) Cause Reaction Remedy • Electrical fault • Engine runs on 5 cylinders • Check that the injector cables are not damaged • Faulty compression or injec- • Abnormal sound tor • Check that the injector con- • Reduced performance nections are not damaged • Check fuel supply pressure • Check the valve clearance • Do a compression test and check cylinder #2 Injector, Cylinder #3 (Code 7.3, SID 3/SPN 653) Cause Reaction Remedy • Electrical fault • Engine runs on 5 cylinders • Check that the injector cables are not damaged • Faulty compression or injec- • Abnormal sound tor • Check that the injector con- • Reduced performance nections are not damaged • Check fuel supply pressure • Check the valve clearance • Do a compression test and check cylinder #3 Injector, Cylinder #4 (Code 7.4, SID 4/SPN 654) Cause Reaction Remedy • Electrical fault • Engine runs on 5 cylinders • Check that the injector cables are not damaged • Faulty compression or injec- • Abnormal sound tor • Check that the injector con- • Reduced performance nections are not damaged • Check fuel supply pressure • Check the valve clearance • Do a compression test and check cylinder #4 Injector, Cylinder #5 (Code 7.5, SID 5/SPN 655) Cause Reaction Remedy • Electrical fault • Engine runs on 5 cylinders • Check that the injector cables are not damaged • Faulty compression or injec- • Abnormal sound tor • Check that the injector con- • Reduced performance nections are not damaged • Check fuel supply pressure • Check the valve clearance • Do a compression test and check cylinder #5 47701683 10-2012 © AB VOLVO PENTA 103 Calibration and Settings, Fault Code Register Injector, Cylinder #6 (Code 7.6, SID 6/SPN 656) Cause Reaction Remedy • Electrical fault • Engine runs on 5 cylinders • Check that the injector cables are not damaged • Faulty compression or injec- • Abnormal sound tor • Check that the injector con- • Reduced performance nections are not damaged • Check fuel supply pressure • Check the valve clearance • Do a compression test and check cylinder #6 Crankcase Ventilation Pressure (Code 7.7, PID/SPN 153) Cause Reaction Remedy • Crankcase ventilation pres- • The engine is shut down (if • Check whether the crankcase sure too high the protection has notbeen ventilation is blocked shut off by the parameter tool) • Check whether cylinder lin- ers, pistons or piston rings are worn or damaged Crankcase Ventilation Pressure Sensor (Code 7.8, PID/SPN 153) Cause Reaction Remedy • Shorted to plus (+) or minus • None • Check that the crankcase (-) ventilation pressure sensor contact is correctly installed • Break • Check that the cable harness to the crankcase ventilation pressure sensor has not been damaged • Check that the crankcase ventilation pressure sensor correctly installed • Check crankcase ventilation pressure sensor function Air Temperature Sensor, Inlet (Code 7.9, PID/SPN 172) Cause Reaction Remedy • Shorted to plus (+) or minus • None • Check that the air tempera- (-) ture sensor contact is cor- rectly installed • Break • Check that the cable harness to the air temperature sensor has not been damaged • Check that the air tempera- ture sensor is correctly instal- led • Check the air temperature sensor functionality 104 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Fault Code Register TWD1643GE ECU Temperature (Code 8.4, PPID 55/SPN 1136) Cause Reaction Remedy • Control unit too hot, incorrect • None • Check the control unit instal- assembly lation. Recommended ambi- ent temperature is 50°C • Electrical fault, damaged sen- (122°F) sor TAD1650VE Internal EGR (Code 8.5, PPID 19/SPN 2791) Cause Reaction Remedy • Fault in cable harness (boost • Engine control module • Check cable harness (boost pressure sensor) reduces engine power pressure sensor) • Mechanical fault on the IEGR • Check the IEGR • Contact a Volvo Penta authorized workshop TAD1650VE, TWD1643GE Preheating Sensor (Code 8.6, SID 70/SPN 729) Cause Reaction Remedy • Fault in cable harness • Preheating can not be acti- • Check the cable harness vated • Fault in preheating relay • Check the preheating relay Faulty data link (J1587) (Code 9.2, SID 250/SPN 608) Cause Reaction Remedy • Faulty data link • None • Check that the 8-pin connec- tor is not damaged • Check that the cables between the CIU/DCU and the engine management unit are not damaged TWD1643GE Power Supply to Sensor (Code 9.3, SID 211, 232/SPN 1080, 1079) Cause Reaction Remedy • Shortcut • Faulty values in oil pressure • Check that the cable harness and boost pressure sensors to oil pressure and boost • Fault in sensor pressure sensor has not been • Fault code for oil pressure- damaged and boost pressure sensor • Check oil pressure and boost • Low engine output pressure sensors • The instrument shows zero oil pressure and boostpressure 47701683 10-2012 © AB VOLVO PENTA 105 Calibration and Settings, Fault Code Register TWD1643GE Power Supply to Sensor (Code 9.3, SID 211/232, SPN 1079/1080) Cause Reaction Remedy • Shortcut • Faulty values in oil pressure • Check that the cable harness and boost pressure sensors to oil pressure and boost • Fault in sensor pressure sensor has not been • Fault code for oil pressure- damaged and boost pressure sensor • Check oil pressure and boost • Low engine output pressure sensors • The instrument shows zero oil pressure and boost pressure Power Supply Sensor (Code 9.3, SID 232/SPN 620) Cause Reaction Remedy • Shortcut • Faulty values in oil pressure • Check that the cable harness and boost pressure sensors to oil pressure and boost • Fault in sensor pressure sensor has not been • Fault code for oil pressure- damaged and boost pressure sensor • Check oil pressure and boost • Low engine output pressure sensors • The instrument shows zero oil pressure and boost pressure Data Set Memory EEPROM, CIU (Code 9.8, SID 253/SPN 630) Cause Reaction Remedy • Internal fault in control mod- • Engine does not start • Re-program the control mod- ule ule. • Programming faulty Fault in Control Unit, CIU (Code 9.8, SID 254/SPN 629) Cause Reaction Remedy • Faulty EEPROM, CIU • CIU returns to factory setting • Re- program the unit • Faulty flash memory, CIU • Engine goes to idle • Fault in control module, CIU • Engine can not be started Memory Fault EMS (Code 9.9, SID 240/SPN 628) Cause Reaction Remedy • Memory fault in engine man- • Engine might not start • Re-program the unit agement system Data Set Memory EEPROM, EMS (Code 9.9, SID 253/SPN 630) Cause Reaction Remedy • Internal fault in control mod- • Engine does not start • Re-program the control mod- ule ule. If the fault remains, change the control module • Internal fault in control mod- ule Control Module EMS (Code 9.9, SID 254/SPN 629) Cause Reaction Remedy • Internal fault in control mod- • Engine misfires • Change engine control unit ule • Engine does not start 106 47701683 10-2012 © AB VOLVO PENTA Calibration and Settings, Fault Code Register TAD1650VE, TWD1643GE Wastegate (SID 32/SPN 1188) Cause Reaction Remedy • Short circuit to positive (+) or • Warning lamp lights up • Check that the wastegate negative (-) connector is properly • Engine control unit limits mounted • Open circuit engine power • Check that the wiring to the • Wastegate damaged wastegate is not damaged mechanically • Check that the wastegate is correctly mounted • Check the wastegate TAD1650VE, TWD1643GE Fan, rpm sensor (PID 26/SPN 975) Cause Reaction Remedy • Open circuit • Warning lamp lights up • Check that the fan actuator is properly mounted • Check that the wiring to the fan actuator is not damaged • Check that the fan actuator is correctly mounted • Check the fan actuator TAD1650VE, TWD1643GE Fan actuator (SID 33/SPN 975) Cause Reaction Remedy • Short circuit to positive (+) or • Warning lamp lights up • Check that the fan actuator is negative (-) properly mounted • Open circuit • Check that the wiring to the fan actuator is not damaged • Fan actuator damaged mechanically • Check that the fan actuator is correctly mounted • Check the fan actuator EATS Fault codes for the EATS system is in the installation manual for this system. 47701683 10-2012 © AB VOLVO PENTA 107 Alphabetical index A Adjustable parameters....................................... 72, 73 Adjustment of speed regulator................................. 74 Alarm limits............................................................... 76 C Calibration and Settings........................................... 71 CAN bus settings...................................................... 79 Communication J1939.............................................. 26 Connection............................................................... 50 Connection of special tool VODIA............................ 71 Control System Installation....................................... 50 D Diagnostic Function.................................................. 92 E Easy Link Instruments.............................................. 62 Electrical interface.............................................. 11, 13 EMS............................................................................ 5 Engine control interface............................................ 13 Engine protection............................................... 77, 78 Engine protection override....................................... 25 F Frequency select...................................................... 24 G General............................................................... 11, 50 Governor mode........................................................ 21 I Idle switch................................................................. 22 In- and out signals...................................................... 8 Installation Tools and Documentation........................ 4 Instruments......................................................... 10, 67 L Location of Sensors.......................... 31, 32, 33, 34, 35 O Other Special Equipment........................................... 4 P Parameter Setting.................................................... 71 Power down sequence............................................. 17 Power supply............................................................ 51 Power up sequence.................................................. 16 Preheat..................................................................... 23 R Rpm-potentiometer................................................... 63 S Safety Information...................................................... 2 Special Tools.............................................................. 4 Synchronizing Engine Speed................................... 70 System Information.................................................... 5 T Throttle (Synchronizing/Load sharing)..................... 19 Torque speed control............................................... 20 W Warning and Indication Lamps................................. 65 Wiring Diagram......................................................... 37 47701683 10-2012 © AB VOLVO PENTA 109 Report form Do you have any comments or complaints about this manual? Please take a copy of this page, write your comments on it and send it to us. The address is at the bottom. We would appreciate it if you were to write in English or Swedish. From:...............................................................................   ........................................................................................ ........................................................................................ ........................................................................................ Refers to publication:................................................................................................................................................ Publication no:.................................................................Date of issue:................................................................... 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Date:................................................................... Name:................................................................. AB Volvo Penta Service Communication Avd. 42200 SE-405 08 Göteborg Sweden 47701683 English 06-2012