Installation: Ems 2 Industrial Engines I
Installation: Ems 2 Industrial Engines I
Installation: Ems 2 Industrial Engines I
EMS 2 1(1)
Industrial Engines
TAD1640GE, TAD1641GE, TAD1642GE
TWD1643GE, TAD1641VE, TAD1642VE
TAD1643VE, TAD1650VE
Content
Safety Information ...................................................................................... 2
Installation Tools and Documentation ...................................................... 4
Special Tools ............................................................................................ 4
System Information .................................................................................... 5
EMS ........................................................................................................... 5
Control System Installation ..................................................................... 23
Connection ............................................................................................. 23
Parameter Setting .................................................................................. 42
Diagnostic Function ............................................................................... 48
Fault Code Register ............................................................................... 51
Alphabetical index .................................................................................... 65
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 7748771 10-2009
Safety Information
Set out below is a summary of the risks and safety measures that must be observed or carried out when the EVC
system is installed and calibrated.
! !
Disconnect connectors to the EMS control unit before 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.
7748771 10-2009 3
Installation Tools and Documentation, Special Tools
Special Tools
p0005125
P0003813 P0003809
P0003811
P0003810 P0003813
P0003811 P0003814
4 7748771 10-2009
System Information, EMS
System Information
EMS
Motorstyrsystem
EMS 2 stands for “Engine Management System” and
is an electronic system with CAN communications
(Controller Area Network) for control of diesel engines.
The system has been developed by Volvo Penta and
includes fuel control and diagnosis function. The 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.
7748771 10-2009 5
System Information, EMS
6 7748771 10-2009
System Information, EMS
Fuel control
7748771 10-2009 7
System Information, EMS
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)
Output signals
The control unit uses the input signals to control the
following components:
- Unit injectors
- Start motor
- Main relay
- Pre-heat relay
- Wastegate (TWD1643GE, TAD1650VE)
- Cold start valve (TWD1643GE)
- Valve mechanism, internal EGR (TAD1650VE)
8 7748771 10-2009
System Information, EMS
Instruments
DCU (Display Control Unit)
DCU is a digital instrument panel that communicates
with the engine control unit via the CAN-link. DCU has
several functions, such as:
Engine control
- Start, stop, rpm regulation, preheating, etc.
Monitoring
- Shows engine speed, charge pressure, charge 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/iso-
chronous).
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
7748771 10-2009 9
System Information, EMS
Location of Sensors
Location of Sensors
TAD1640GE, TAD1641GE, TAD1641VE,
TAD1642GE, TAD1642VE, TAD1643VE
1 2
11
4
10
5
12
6
9
8
7
14
13
P0002058
10 7748771 10-2009
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 the expansion tank 9 Combined oil level and oil temperature sensor
2 Combined charge air pressure and charge air tem- 10 Crankcase pressure sensor
perature sensor
3 Oil pressure sensor 11 Coolant temperature sensor
4 Under-pressure sensor, air filter 12 Exhaust temperature sensor
5 Extra stop (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
7748771 10-2009 11
System Information, EMS
Location of Sensors
TAD1650VE
1 2 3
7
8 5
66
10
12
11
P0005187
1 Crankcase pressure sensor 7 Combined oil level and oil temperature sen-
sor
2 Combined charge air pressure and charge air tempera- 8 “Water in fuel” sensor
ture sensor
3 Flywheel position and engine speed sensor 9 Fuel pressure sensor
4 Fuse 10 Coolant temperature sensor
5 Extra stop (Aux stop) 11 Piston cooling pressure sensor
6 Oil pressure sensor 12 Camshaft position sensor
12 7748771 10-2009
14
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
System Information, EMS
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
SB
(3) (4) B SB
(2) (1) P2
CAN j1939
1
R 2,5
CAN 2
(1) (2)
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
TAD1642GE, TAD1642VE
Wiring Diagram
28 27
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
TAD1640GE, TAD1641GE, TAD1641VE,
26
P0004301 22
7748771 10-2009
System Information, EMS
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.
7748771 10-2009 15
System Information, EMS
TWD1643GE
16 7748771 10-2009
System Information, EMS
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.
7748771 10-2009 17
11
18
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
System Information, EMS
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
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
7748771 10-2009
System Information, EMS
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.
7748771 10-2009 19
System Information, EMS
20 7748771 10-2009
System Information, EMS
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.
7748771 10-2009 21
System Information, EMS
12345678 8
11
W/SB
Y/W
R 2,5
GR/Y
SB 2,5
BL 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 Stoppkontakt Kabelfärger
2 Startkontakt BL = Blue
3 1-poligt kontaktdonsblock LBL = Lightblue
BN = Brown
4 Signalhorn, larmsummer LBN = Lightbrown
5 Kontaktblock Easy Link GN = Green
GR = Grey
6 Varvtalspotentiometer OR = Orange
7 Gångindikering P = Pink
R = Red
8 Deutsch 8-poligt kontaktdon, engine interface SB = Black
9 Deutsch 8-poligt kontaktdonshylsa, engine interface VO = Violet
W = White
10 Termineringsmotstånd 120 Ω Cable area = 0.75 mm2 unless
11 DCU (Display Control Unit) otherwise specified.
22 7748771 10-2009
Control System Installation, Connection
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.
7748771 10-2009 23
Control System Installation, Connection
30
31
P0003815
24 7748771 10-2009
Control System Installation, Connection
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
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).
7748771 10-2009 25
Control System Installation, Connection
TWD1643GE
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
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).
26 7748771 10-2009
Control System Installation, Connection
CIU
TAD1640GE, TAD1641GE, TAD1642GE,
TWD1643GE
A E
P0004306
A 8-pin Deutsch connector, from wire harness to engine D For the connection cable, refer to the Instru-
ments page 38 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
7748771 10-2009 27
Control System Installation, Connection
Engine control
Refer to System Information page 14 CIU
NO = normally open
NC = normally closed
Start switch
Switch type: closing (NO), spring loaded.
Stop switch
Switch type: closing (NO), spring loaded.
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
P0005828
28 7748771 10-2009
Control System Installation, Connection
Idle switch
Two-position contact.
Closed contact provides idle rpm (900 rpm).
Contact, pre-heating
Two-position contact.
7748771 10-2009 29
Control System Installation, Connection
CIU
TAD1641VE, TAD1642VE, TAD1643VE, TAD1650VE
A 8-pin Deutsch connector, from wire harness to engine D For the connection cable, refer to the Instru-
ments page 38 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
30 7748771 10-2009
Control System Installation, Connection
Engine control
Refer to System Information page 14 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.
P0003965
A Stop contact
B ON contact
C Start lock
D Pre-heating contact
A
B
C
D
P0003966 E
A Pre-heating
B Start
C Batt +
D 15 start lock
E Stop
7748771 10-2009 31
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)
Idle switch
The accelerator pedal has an integral idle switch that
acts as an emergency device if the accelerator pedal
A potentiometer becomes defective.
P0004058
32 7748771 10-2009
Control System Installation, Connection
DCU
C
A
P0005826
7748771 10-2009 33
Control System Installation, Connection
Display (optional)
Switch type: closing (NO), spring loaded.
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
TAD1641VE, TAD1642VE, TAD1643VE, TAD1650VE
34 7748771 10-2009
Control System Installation, Connection
P0005815
P0005816
7748771 10-2009 35
Control System Installation, Connection
Rpm-potentiometer
TAD1640GE, TAD1641GE, TAD1642GE,
TWD1643GE
A A
B
B
C C
1V 5V 9V 1V 5V 9V
P0005824
P0005825
36 7748771 10-2009
Control System Installation, Connection
Max. power 3 W
Voltage 24 V
Max. power 3 W
Voltage 24 V
7748771 10-2009 37
Control System Installation, Connection
Instruments
Easy Link Instrument (option)
Refer to the System Information page 14 for the appli-
cable engine.
• Oil temperature
• Battery voltage
P0005053
P0005052
P0005051
A 3-pin connector
B 3-pole connector
C CIU wiring harness
38 7748771 10-2009
Control System Installation, Connection
Tachometer
Use Volvo Penta standard tachometer, graduations 0–
2,600 rpm.
Setting code 14. Refer to installation instructions.
P0003961
P0003961
P0003961
7748771 10-2009 39
Control System Installation, Connection
Diagnostics switch
Switch type: closing (NO), spring loaded. For reading
fault codes, refer to the Control System Installa-
tion page 48 chapter.
Contact, pre-heater
Switch type: closing (NO), spring loaded. This contact
activates the pre-heating.
P0003961
40 7748771 10-2009
Control System Installation, Connection
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.
A
B A
C
7748771 10-2009 41
Control System Installation, Parameter Setting
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
42 7748771 10-2009
Control System Installation, Parameter Setting
Adjustable parameters
TAD1640GE, TAD1641GE, TAD1642GE
Idling speed
Setting idle revolutions.
Min. value: 600 rpm
Preset value: 900 rpm
Max. value: 1200 rpm
7748771 10-2009 43
Control System Installation, Parameter Setting
Adjustable parameters
TAD1641VE, TAD1642VE, TAD1643VE, TAD1650VE
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”
44 7748771 10-2009
Control System Installation, Parameter Setting
Alarm limits
TAD1640GE, TAD1641GE, TAD1642GE,
TWD1643GE
Alarm limits
TAD1641VE, TAD1642VE, TAD1643VE, TAD1650VE
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)
7748771 10-2009 45
Control System Installation, Parameter Setting
Engine protection
TAD1640GE, TAD1641VE, TAD1642GE,
TWD1643GE
46 7748771 10-2009
Control System Installation, Parameter Setting
Engine protection
TAD1641VE, TAD1642VE, TAD1643VE, TAD1650VE
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”
7748771 10-2009 47
Control System Installation, 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 inform-tion is presented in.
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
48 7748771 10-2009
Control System Installation, Diagnostic Function
DU (Display Unit)
• Either WARNING! or ALARM STOP (a buzzer
sounds) will be shown on the display, depending
on the severity of the fault.
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.
7748771 10-2009 49
Control System Installation, 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.
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.
50 7748771 10-2009
Control System Installation, Fault Code Register
For references to sleeves in electrical connectors, refer to System Information page 14.
TWD1643GE
7748771 10-2009 51
Control System Installation, Fault Code Register
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
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Control System Installation, Fault Code Register
7748771 10-2009 53
Control System Installation, Fault Code Register
54 7748771 10-2009
Control System Installation, Fault Code Register
TWD1643GE
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Control System Installation, Fault Code Register
56 7748771 10-2009
Control System Installation, Fault Code Register
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
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Control System Installation, Fault Code Register
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Control System Installation, Fault Code Register
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Control System Installation, Fault Code Register
60 7748771 10-2009
Control System Installation, Fault Code Register
TWD1643GE
TAD1650VE
TAD1650VE, TWD1643GE
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
7748771 10-2009 61
Control System Installation, Fault Code Register
TWD1643GE
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
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
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Control System Installation, Fault Code Register
TAD1650VE, TWD1643GE
TAD1650VE, TWD1643GE
TAD1650VE, TWD1643GE
7748771 10-2009 63
Alphabetical index
Adjustable parameters.................................... 43, 44
Alarm limits.............................................................. 45
CIU.................................................................... 27, 30
Connection.............................................................. 23
Connection of special tool VODIA........................... 42
Control System Installation...................................... 23
DCU......................................................................... 33
Diagnostic Function................................................. 48
Easy Link Instruments.......................................... 34
EMS........................................................................... 5
Engine protection.............................................. 46, 47
Fault Code Register.............................................. 51
General................................................................... 23
In- and out signals................................................... 8
Installation Tools and Documentation....................... 4
Instruments................................................................ 9
Instruments.............................................................. 38
Location of Sensors.............................................. 10
Location of Sensors..................................... 10, 11, 12
Other Special Equipment........................................ 4
Parameter Setting.................................................. 42
Rpm-potentiometer............................................... 36
Safety Information................................................... 2
Special Tools............................................................. 4
Synchronizing Engine Speed.................................. 41
System Information................................................... 5
Warning and Indication Lamps............................ 37
Wiring Diagram........................................................ 14
7748771 10-2009 65
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Teknisk Information
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7748771 English 10-2009