VOLVO 7748542 - US - Installation EMS 2 - D13

Installation
EMS 2
Industrial Engines
I
1(1)
TAD1341GE, TAD1342GE, TAD1343GE, TAD1344GE

TAD1345GE, TAD1350GE, TAD1351GE, TAD1352GE
TAD1353GE
TAD1340VE, TAD1341VE, TAD1342VE, TAD1343VE
TAD1344VE TAD1345VE
Content
Safety Information ...................................................................................... 2
Installation Tools and Documentation ...................................................... 4
Special Tools ............................................................................................ 4
System Information .................................................................................... 5
EMS ........................................................................................................... 5
Control System Installation ..................................................................... 17
Connection ............................................................................................. 17
Parameter Setting .................................................................................. 34
Diagnostic Function ............................................................................... 40
Fault Code Register ............................................................................... 43
Alphabetical index .................................................................................... 57
Safety Information
Presentation
Working methods
This installation manual contains information for

installing and carrying out function and performance
checks on the EMS 2 system (electronic control of the
injection system).
This instruction manual is intended only for professional use.
Read the instructions carefully before starting the
installation. If the installation is performed in an incorrect manner, it may cause personal injury or damage
to property and machinery.
Ask your Volvo Penta dealer for help if there is anything in this manual that you do not understand or are
uncertain about.
The work must be performed by a Volvo Penta workshop or other authorized, well-equipped workshop by
qualified and experienced personnel.
These instructions refer to such personnel as fitters.
This installation manual is intended to be used
together with the operator's manual for the engine
concerned. The fitter is responsible for ensuring that
the system functions in accordance with these installation instructions.
Volvo Penta disclaims all responsibility for injury to
persons or damage to property that may occur as a
result of not following the installation guidelines, or for
work carried out by unqualified personnel.
!
This symbol is used in the manual and on the product to call attention to the fact that
this is safety information. Always read such information very carefully.
Safety texts in the installation manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT!
Indicates a situation which, if not avoided, could result in property damage.
NOTICE! Used to draw attention to important information that will facilitate work or
operations.
This symbol is used on our products in certain cases and it refers to important
information in the operator's manual. Make sure that warning and information symbols
on the engine are clearly visible and legible. Replace symbols that have been damaged
or painted over.
7748542 10-2009
Safety Information
Set out below is a summary of the risks and safety measures that must be observed or carried out when the EVC
system is installed and calibrated.
!
Disconnect connectors to the EMS control unit before
any arc welding is carried out.
Turn the current off at the main switches.
Undo and remove the control unit connectors.
Reconnect the EMS 2 control unit connectors once
welding is completed and the welding equipment has
been removed.
!
Take care to keep clear of the engine's moving parts
during functional checks and operations. There is a
risk for personal injury when approaching a running
engine. Remember that loose clothing and long hair
can fasten in rotating parts and cause serious injury.
!
Never work on an engine that is suspended from lifting
gear (a crane or similar).
!
The engine must not be run in areas where there are
explosive materials or gases.
!
Only start the engine in well-ventilated places. If the
engine is operated in an enclosed space, make sure
that there is sufficient ventilation to remove the
exhaust gases and crankcase fumes from the workplace.
7748542 10-2009
!
Never expose battery compartments to open flames
or electrical sparks. Never smoke in the vicinity of the
batteries.
Batteries generate hydrogen gas during charging,
which can combine with air to form an explosive mixture. This gas is highly flammable and explosive.
Incorrect connection of the batteries may cause
sparks that in turn cause an explosion resulting in
damage.
Do not switch battery connections when attempting to
start the engine (risk for sparks) and do not lean over
the batteries. Refer to the instructions in the engine
operator's manual.
!
Make sure that the positive (+) and negative (-) battery
cables are correctly connected to the corresponding
battery terminals. Serious damage may be caused to
the electrical equipment if the cables are transposed.
Refer to the wiring diagram in the engine operator's
manual.
!
Always wear eye protection when charging or handling the batteries. Battery electrolyte contains sulfuric acid which is highly corrosive. If electrolyte comes
into contact with bare skin, wash the exposed area
immediately with copious amounts of clean water and
soap. Then seek medical attention. If you get battery
electrolyte in your eyes, flush them immediately (preferably using eye wash equipment) with copious
amounts of clean water. Then seek immediate medical attention.
Installation Tools and Documentation, Special Tools
Installation Tools and Documentation

Special Tools
p0005125
3838619 VODIA, diagnostic

tool
VODIA, complete with cable harness
Refer to the VODIA operators
manual when ordering separate
parts.
9812519 Multimeter
Multimeter
Other Special Equipment

Other special equipment
The tools below are used for work on the engine wire harness. The tools are not part of the Volvo Penta range,
and must be ordered from AMP or Deutsch dealers. Contact Volvo Penta Quality Action Center if you have trouble
finding a dealer.
AMP connector: 42-pin CIU, 62-pin EMS, 2 and 3 pin Bosch etc.
P0003813
HDT-4800
Press tool
P0003810
AMP 726 519

Removal tool, 2.8 mm pin width
P0003811
AMP 825 514

Press tool
For 4.8 and 6.3 cable shoes.
Flat-pin connectors.
AMP 539 968

P0003809
AMP 726 519

Removal tool, 0,06 inch pin width
P0003811
P0003813
AMP 929 039

AMP 238 635

Press tool
P0003814
GHW 50000 017 586

For GHW connector (relay box)
7748542 10-2009
System Information, EMS
System Information
EMS
Motorstyrsystem
EMS 2 stands for Engine Management System and
is an electronic system with CAN communications
(Controller Area Network) for control of diesel engines.
The system has been developed by Volvo Penta and
includes fuel control and diagnosis function. The system consists of a control module, six unit injectors, a
number of sensors that supply the control module with
measurements, sockets for diagnosis and functional
checks. The engine can be connected to a communication interface comprising a CAN-link and a serial link.
CAN (Controller Area Network)

The CAN J1939 link handles all communication
between the engine control module EMS 2 and the
CIU, in addition to the diagnostics that are handled by
the so called J1708/J1587 link. The CAN link is much
faster than the J1708/J1587 link. The CAN link has
been prepared to connect to other components with
SAE J1939 protocol such as instrument panels and
transmissions.
If, for some reason, a fault develops on the CAN link,
signals for the rpm-potentiometer and the start and
stop knobs are taken over by the J1708/J1587 link.
However, instrument and indicator lamps are completely turned off. If a fault occurs on both links, GE
engines maintain engine speed, while VE engines go
to idle. The only way to shut off the engine in this case
is to use the auxiliary stop (AUX-STOP) placed on the
engines left side.
7748542 10-2009
CIU (Control Interface Unit)

The CIU is a translator between the CAN bus and the
customers own control panel. This unit has two serial
communication links, one fast and one slow. The fast
one is a CAN link that features a bus speed of 250 Kbit/
s. All data regarding instruments, indicator lamps, contacts and potentiometers are controlled by this bus.
The slower J1708/J1587 link handles diagnostic information for, among other things, the flashing code. The
diagnosis tool VODIA also uses the J1708/J1587 link
to communicate with the system.
P0002060
7748542 10-2009
Fuel control
The engines fuel requirement is analyzed up to 100
times per second (depending on engine rpm). The
engines injection amount and injection timing is controlled electronically via fuel valves on the unit injectors.
This means that the engine always receives the correct volume of fuel in all operating conditions, which
offers lower fuel consumption, minimal exhaust emissions etc.
The control module checks and controls the unit injectors so that the correct amount of fuel is injected into
each cylinder. It calculates and sets the injection
angle. The control is primarily performed using the
speed sensors and the combined sensor for boost
pressure/charge air temperature.
The control module affects the unit injectors via an
electronic signal to the unit injectors electromagnetic
fuel valve, which can open and close.
When the fuel valve is open, fuel flows through the
unit injector hole and out through the fuel channel.
Fuel is not sprayed into the cylinder in this position.
When the fuel valve closes, pressure starts to build
from the unit injectors mechanically operated pump
plunger. When sufficient pressure has developed, fuel
is injected into the cylinder via the unit injectors injector section.
The fuel valve is re-opened and pressure in the unit
injector decreases at the same time as the fuel injection to the cylinder stops.
In order to determine when the fuel valve shall open
or close, the control module has access to signals
from sensors and switch contacts.
Altitude correction
The control unit is fitted with an atmospheric air pressure sensor and an altitude correction function for
engines operating at high altitudes. This function limits the fuel volume in relation to ambient air pressure.
This is to prevent smoke, high exhaust temperature
and to protect the turbocharger from over-speeding.
Diagnosis function
The task of the diagnosis function is to detect and
locate disturbances within the EMS 2 system, to protect the engine, and to provide information about
problems that have developed. If a malfunction is discovered, this is announced by warning lamps, a flashing diagnostic lamp or in plain language on the instrument panel, depending on the equipment used. If a
fault code is obtained as a flashing code or in plain
language, this is used for guidance in any troubleshooting. Fault codes can also be read by Volvos
VODIA tool at authorized Volvo Penta workshops. In
case of serious malfunctions, the engine is shut down
completely, or the control unit reduces the power output (depending on application). A fault code is set as
a guide when fault tracing.
Calculating fuel quantity

The amount of fuel that is sprayed into a cylinder is
calculated by the control module. The calculation
determines the time that the fuel valve is closed (when
the fuel valve is closed fuel is sprayed into the cylinder).
The parameters controlling injected amount of fuel
are:
Requested engine speed
Motor protector
Temperature
Boost air pressure
7748542 10-2009
In- and out signals

Information from the sensors provides accurate information regarding operational conditions and makes it
possible for the control unit processor to calculate the
correct injection amount, injection timing and engine
condition, among many other things.
Input signals
The control unit receives input signals regarding
engine operational conditions along with information
from the following components:
- Coolant temperature sensor
- Charge air pressure/charge air temperature sensors
- Crankcase pressure sensor
- Position sensor
- Camshaft
- Engine speed sensor
- Flywheel
- Piston cooling pressure sensor
- Coolant level sensor
- Oil pressure sensor
- Oil level and oil temperature sensors
- Fuel pressure sensor
- Water-in-fuel sensor
- Air filter pressure sensor
- Air temperature sensor
- Fan speed
Output signals
The control unit uses the input signals to control the
following components:
- Unit injector
- Start motor
- Alternator
- Main relay
- Preheat relay
- Internal EGR (TAD1350-1353GE only)
- Waste gate
- Electronic fan control
7748542 10-2009
Instruments
DCU (Display Control Unit)
DCU is a digital instrument panel that communicates
with the engine control unit via the CAN-link. DCU has
several functions, such as:
Engine control
- Start, stop, rpm regulation, preheating, etc.
Monitoring
- Shows engine speed, charge pressure, charge temperature, coolant temperature, oil pressure, oil temperature, engine hours, battery voltage, instantaneous fuel consumption and fuel consumption (trip
fuel).
Diagnostic
- Shows fault codes in text. Lists previous faults.
Parameter setting
- Idle speed, alarm limits for oil temperature/coolant
temperature, regulation mode (speed droop/isochronous).
DU (Display Unit)
DU is an instrument for showing the engines operating
values. The values are shown graphically on an LCD
display. The display communicates via the CAN link
and consists of a computerized unit for attachment to
the control panel.
It is connected to the CAN link between the engine
control unit and CIU or DCU.
P0002061
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Location of Sensors
2
8
4
7
5
6
9
14
10
13
12
11
P0004318
1. Extra stop
8. Fan, rpm sensor
2. Combined charge air pressure and charge air

temperature sensor
9. Under-pressure sensor, air filter
3. Oil pressure sensor

4. Crankcase pressure sensor
5. Water-in fuel sensor
6. Combined oil level and oil temperature sensor
10. Coolant level sensor, in the expansion tank

11. Coolant temperature sensor
12. Piston cooling pressure
13. Flywheel position and engine speed
14. Camshaft position
7. Fuel pressure sensor
10
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GN/R
SB
18
17
SB
R
2P 1
25
P2
12
30
SB 4
R1
SB 2
28 27 23 14
1P
15
21
10
SB
SB
SB
12 3 4 5 6 7
CAN 2
GR/OR
SB
R 1,0
1
3 P2
26
R 3
SB
1
BN/OR
GR/GN
32
BC AE D F
P4
21
n
14
21
n
13
Y 1,0
Y 1,0
SB 1,0
GN
BL/GB
Y 1,0
31
1 2
16
Y 1,0
Y 1,0
1
R/BL 1,5
1 Y 1,0
2 1 Y 1,0
CYL. 6
4 3 Y 1,0
2 1 Y 1,0
CYL. 5
4 3 Y 1,0
2 1 Y 1,0
CYL. 4
4 3 Y 1,0
2 1 Y 1,0
CYL. 3
4 3 Y 1,0
2 1 Y 1,0
CYL. 2
4 3 Y 1,0
CYL. 1
4 3 Y 1,0
60 61
59 62
4 5 6
R/BL 1,0
HL
b a
33 34 27 58 57
52 56 30 38 29 25 37 57 60 7 58 59 61 51 55
h l
h
h l
CONNECTOR A
31 11 7
47 22 15 29 35 39 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24
- +
-
49
3 4 31 11 16
CONNECTOR B
1
2
SB
22
GN/SB
GN/W
BL/GN
BL/OR
R
2P 1
OR
BN 1,0
R 1,0
SB
23
Y 1,0
SB 1,0
GN
BL
OR/SB
GB/SB
Y 1,0
Y 1,0
24
Y 1,0
Y 1,0
Y/SB
OR 1,0
R/W
Y 1,0
SB
GR/SB
VO/SB
BL/W
MAIN RELAY HOLD
W/SB
W
GR/R
BN/OR
LBN
GR/R
Y 1,0
Y 1,0
SB 1,5
SB 1,5
29
BL
SB 1,0
Y 1,0
Y 1,0
R/BL
Y 1,0
R/BL 1,5
R/BL 1,5
R/BL 1,5
CAN
J1939
SB 1,5
1 2345
B+
B-
20
18
R 25
SB 25
7 8
AB
1 2 3 4 5 6
10
R 25
SB 25
17
4 231
4 231
SB 1,0
R
W/SB
SB
BN 1,0
R/BL 1,0
Y/W
GR/Y
Y/W
GR/Y
R/BL 1,5
Y
Y 1,0
Y 1,0
BN 1,0
SB 1,5
Y/SB
SB 2,5
-.
BATT
R 2,5
. + BATT SWITCHED
. + BATT
R/BL 1,5
BL
STOP
J1587
W
1708
W/SB
R/BL 1,5
W
SB 2,5
OR 1,0
31
SB 2,5
R 2,5
R/W
Y/SB
R 2,5
11
30
19
1 2
27
28
85
Y/SB
1
R/BL 1,5 2
30
R 1,5
4
R
3
5
R/BL 1,0
12
1 2
5
86
87
Wiring Diagram
P0010912
7748542 10-2009

1 Battery (24 V)
2 Main Switch
3 Start motor
4 Alternator
5 Power relay failure
6 Auxiliary stop
7 Connectors, engine
8 Sensor, coolant temperature
9 Sensors, charge air pressure/charge air temperature
10 VODIA socket (diagnostics socket)
Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
Vo = Violet
W = White
Y = Yellow
Wire cross-sectional area = 0.75 mm unless otherwise stated.
11 Connector (not used)

12 Sensor, crankcase pressure
13 Sensor, camshaft
14 Sensor, flywheel
15 Sensor, piston cooling pressure
16 Unit injectors(cyl. 1-6)
17 Preheat relay
18 Circuit breaker
19 Main circuit breaker 10 A
20 Preheater
21 Sensor, coolant level
22 Sensor, oil pressure/temperature
23 Sensor, water in fuel
24 Sensor, oil pressure
25 Sensor, fuel pressure
26 Air filter indicator
27 Stop button
28 Jumper
29 Internal EGR (TAD13501353GE only)
30 Control unit, EMS 2.2
31 Wastegate Valve
32 Electric fan
7748542 10-2009
13

14
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Key switch, operating current (15+)

RPM-potentiometer
Tachometer (code 14)
Oil pressure, instrument
Oil temperature, instrument
Coolant temperature, instrument
Instrument illumination
Idle contact, two position
1500/1800 contact, two position
Start switch, spring return
Stop switch, spring return
Diagnosis contact, spring return
Alarm, low oil pressure
Alarm, high oil temperature
Alarm, high coolant temperature
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Alarm, low coolant level

Fuel alarm
Diagnostic lamp
Overspeed indication (GE)
Operation indicator
Preheating indication
Preheating contact
8-pin Deutsch connecting plug, engine interface
Governor contact
Battery voltage alarm
Termination resistance 120 Ohm
8-pin Deutsch connecting socket
Contact, engine protector disconnect
Easy Link connector block
Control Interface Unit (CIU)
Cable colors
BL
= Blue
LBL = Light blue
BN
= Brown
LBN = Light brown
GN
= Green
GR
= Grey
OR
= Orange
P
= Pink
R
= Red
SB
= Black
VO
= Purple
W
= White
Y
= Yellow
Cable cross section =0.75 mm2 unless other-wise stated.
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15

12345678 8
Y/W
GR/Y
SB 2,5
R 2,5
R/BL 2,5
BL 2,5
W/SB
Y/W
GR/Y
SB 2,5
R 2,5
R/BL 1,5
BL 2,5
W
W/SB
Y/W
GR/Y
SB 2,5
R 2,5
R/BL 1,5
BL 2,5
W
W/SB
11
3
1
D
C 2
U
3
VO
R/Y
12345678 9
1 2 3 4 5 6 7 8 10
SB/Y
R/BL
SB
GN/R
GN/Y
GN/SB
10
SB/VO
11
SB/GR
12
SB/W
1
3
2
6
7
P0004305
1 Stoppkontakt
Kabelfrger
2 Startkontakt
BL = Blue
LBL = Lightblue
BN = Brown
LBN = Lightbrown
GN = Green
GR = Grey
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Cable area = 0.75 mm2 unless
otherwise specified.
3 1-poligt kontaktdonsblock
4 Signalhorn, larmsummer
5 Kontaktblock Easy Link
6 Varvtalspotentiometer
7 Gngindikering
8 Deutsch 8-poligt kontaktdon, engine interface
9 Deutsch 8-poligt kontaktdonshylsa, engine interface
10 Termineringsmotstnd 120
11 DCU (Display Control Unit)
16
7748542 10-2009
Control System Installation, Connection
Control System Installation

Connection
General
The installation must be prepared for well and carried out with the greatest care.
Secure the connecting cable between the engine
and instrument panel with clamps. Bear in mind that

connector blocks must be mechanically secured so
that they are not exposed to any pulling forces.
The cables must not be run close by hot engine
components or close to any other heat source.

Ensure that the cables are protected from mechanical wear, sharp edges and water splashes. If necessary, the cables can be run through conduits.
As far as possible, avoid splices in the system wir-
ing. The cables and any splices must be accessible

for inspection and service.
NOTICE! Connectors must be assembled dry, they

must not be filled with petroleum jelly or similar.
7748542 10-2009
17
Power supply
NOTICE! The engines are equipped with a 2-pole electrical system. This means that the positive and negative cables from the battery must be connected to the
starter motor terminals.
The positive cable from the battery may be run via a
main switch to terminal 30 on the starter motor.
The negative cable from the battery must be connected directly to terminal 31 on the starter motor.
Refer to the illustration below.
30
31
P0004300
18
7748542 10-2009
Battery specification
Max. battery 2x220 Ah (series connected), 1150 A
CCA EN.
Battery charging
Standard for all engines is that batteries are supplied
with power from the alternator.
Battery cable cross-sectional area

The total length (L) of the positive and negative cables
determines the cable cross sectional area (A).
Max L
(m)
(ft)
8
26.2
10
32.8
13
42.6
Min A
(mm2)
(in2)
70
0.11
95
0.15
120
0.19
WARNING!
Due to fire risk, the cable area should never be less
than 70 mm2 (0.1 inch2).
7748542 10-2009
19
CIU
TAD1341GE, TAD1342GE, TAD1343GE,
TAD1351GE, TAD1352GE, TAD1353GE
F
P0004306
A 8-pin Deutsch connector, from wire harness to engine

B Connectors, analog instruments
C 3-pin Deutsch connector, Easy Link instrument
20
D For the connection cable, refer to the Instruments page 30 section.

E 8-pin Deutsch connector
F Extension cables, available in the following lengths: 3,
5, 7, 9, and 11 m
7748542 10-2009
Engine control
Refer to System Information page 12 CIU
NO = normally open
NC = normally closed
Start lock (system voltage OFF / ON)
Engine system voltage start current (control unit) is 10
A. Ensure that other components in the installation are
dimensioned for this current load.
Start switch
Switch type: closing (NO), spring loaded.
Stop switch
The stop switch is energized during operations via a
parameter setting. In this case use a normally closed
(NC) switch.
RPM potentiometer
Nominal revolutions minus 90 rpm: 0.31.9 V (preset
value 1.17 V)
Nominal revolutions plus 90 rpm: 1.94.7 V (preset
value 4.5 V)
A
B
C
P0005827
1.17 V
2.84 V
4.5 V
P0005828
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21

1800 rpm switch
Two-position contact.
Idle switch
Closed contact provides idle rpm (900 rpm).
Droop value switch
The switch must be closed to provide rpm droop value.
Primary control switch
Contact, pre-heating
22
7748542 10-2009
CIU
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE
A 8-pin Deutsch connector, from wire harness to engine

B Connectors, analog instruments
C 3-pin Deutsch connector, Easy Link instrument
7748542 10-2009
D For the connection cable, refer to the Instruments page 30 section.

E 8-pin Deutsch connector
F Extension cables, available in the following lengths:
3, 5, 7, 9, and 11 m
23
Engine control
Refer to System Information page 12 CIU
NO = normally open
NC = normally closed
Start lock
The start lock switch is used to connect the system
power, pre-heating and start and stop functions.
Engine system voltage start current (control unit) is 10

A. Ensure that other components in the installation are
dimensioned for this current load.
P0003965
Stop contact
ON contact
Start lock
Pre-heating contact
Start lock positions
Position 0: engine switched OFF

Position I: system voltage ON
Position II: pre-heating ON (spring return)
Position III: start motor ON (spring return)
Position S: stop function ON (spring return)
P0003966
Pre-heating
Start
Batt +
15 start lock
Stop
24
A
B
C
D
E
7748542 10-2009

Control switch
Accelerator pedal
Idle: 0.3 1.9 V (preset value 1.17 V)
Full throttle: 1.9 4.7 V (preset value 4.5 V)
If an accelerator pedal with different resistance and
voltage values is used, the control unit must be re-calibrated using the parameter tool; refer to Connection of
special tool VODIA page 34.
A
B
Idle switch
The accelerator pedal has an integral idle switch that
acts as an emergency device if the accelerator pedal
potentiometer becomes defective.
When the accelerator pedal is depressed, a contact is
closed and the engine increases in steps to 80 percent
of maximum rpm. When the accelerator pedal is
released, the contact is opened and the engine slows
to idle immediately.
P0004058
7748542 10-2009
25
DCU
C
A
P0005826
8-pin connector from the engine wire harness.
3-pin Deutsch connector, Easy Link instrument
Connectors, analog instruments (options)
26
7748542 10-2009

The DCU is connected via the 8-pin databus connector
block.
Display (optional)
Stop switch (optional)
Warning and control lamps (options)
Running indication:
Max. power 3 W
Voltage 24 V
7748542 10-2009
27
Rpm-potentiometer
The values from the rpm potentiometer in-I or output
signal from the connection to an external load distribution system can be set in the DCU.
Nominal revolutions minus 120 rpm: 010 V (preset
value 1 V)
Nominal revolutions plus 120 rpm: 010 V (preset
value 9 V)
It is possible to invert the signal; see diagram.
C
P0005824
C
1V
5V
9V
P0005825
1V
5V
Nominal revolutions + 120 rpm
Nominal revolutions + 120 rpm
Nominal revolutions (1500/1800 rpm)
Nominal revolutions - 120 rpm
Nominal revolutions - 120 rpm
9V
Rpm-potentiometer
It is possible to invert the signal; see the diagram
below.
P0005815
P0005816
Max. potentiometer value: 010 V (preset value 9V)

Min. potentiometer value: 010 V (preset value 1V)
28
7748542 10-2009
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 CIU System Information page 12.

Alarm, low fuel level
Alarm, low battery voltage
Diagnostic lamp
Pre-heat indicator
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 CIU System Information page 12.

Alarm, low fuel level
Alarm, low battery voltage
Diagnostic lamp
Pre-heat indicator
7748542 10-2009
29
Instruments
Easy Link Instrument (option)
Refer to the System Information page 12 for the applicable engine.
For parallel connection of up to 20 extra VDO instruments.
The instruments will automatically find their own
parameter group from the databus. Maximum Easy
Link cable length is 3 m.
The following instruments are available:
Tachometer/operating hours
Coolant temperature
Oil pressure
P0005054
Oil temperature
Battery voltage
Retaining collar
Retaining bracket
P0005053
P0005052
Extension cable, 3-pole, 1 m
P0005051
30
3-pin connector
3-pole connector
CIU wiring harness
7748542 10-2009
Instrument, analog (option)

Refer to the System Information page 12 for the applicable engine.
Tachometer
Use Volvo Penta standard tachometer, graduations 0
2,600 rpm.
Setting code 14. Refer to installation instructions.
P0003961
Oil pressure gauge

Use Volvo Penta oil pressure gauge, graduations 0
10 bar (0145 psi).
P0003961
Oil temperature gauge

Use Volvo Penta oil temperature gauge, graduations
40150 C (104302 F).
P0003961
7748542 10-2009
31

Coolant temperature gauge
Use Volvo Penta oil temperature gauge, graduations
40150 C (105300 F).
Diagnostics switch
Switch type: closing (NO), spring loaded. For reading
fault codes, refer to the Control System Installation page 40 chapter.
Contact, pre-heater
Switch type: closing (NO), spring loaded. This contact
activates the pre-heating.
P0003961
32
7748542 10-2009
Synchronizing Engine Speed

Synchronization/load distribution
The system is adapted for GAC synchronization and
load distribution. Use the EAM122 interface module
when connecting to this system. When this system is
used, voltage levels must be adjusted simultaneously
with VODIA, according to the below.
NOTICE! The EAM122 interface module is not sold by
Volvo Penta. Contact a GAC (Governors of America
Corporation) dealership.
A
B
C
A
B
C
0.7 V
2.75 V
4.8 V
P0005829
P0003964
Rpm control (GN/NO)
Rpm control (GN/SB)
Contact to (R/BL 1.5)
7748542 10-2009
Nominal revolutions +120 rpm
Nominal revolutions 120 rpm
33
Control System Installation, Parameter Setting
Parameter Setting
Connection of special tool VODIA
Connection of special tool VODIA
P0001169
Function
It is possible to read and adjust parameters with the
VODIA tool, part no.3838619, as described in the following pages.
The VODIA tool is connected to the diagnostic outlet
6-pin connector located on the left side of the engine.
Refer to the VODIA user directions for instructions.
34
7748542 10-2009
Adjustable parameters
NOTICE! Some parameters require special authorization.
Primary regulator mode
Indicated engine rpm inverted value
Selects the regulator to be used when the regulator

contact is closed.
Alternative modes: Isochronous or Droop value
Preset mode: Isochronous

contact is closed.
Alternative engine revolutions: 1500 rpm or 1800
rpm.
Preset rpm: dependent on the specification ordered.
PTO regulator gradient is used
Maximum engine revolutions (CIU)
The gradient is defined either by a droop value in percent if the Regulator roop value parameter is equal to
zero or Nm/rpm if the Regulator gradient parameter is
equal to zero.
Potentiometer signal voltage on the CIU unit corresponding to nominal revolutions (1500/1800 rpm) plus
+/- 90 rpm.
Min. value: 1.90 V
Max. value: 4.70 V
Preset value: 4.50 V
Regulator droop value
Pre-heating for ignition
Selects the droop value magnitude to be used when

droop value is activated (percent).
Min. value: 0 %
Max. value: 8 %
Preset value: 4 %
Selects whether pre-heating and post heating is to be

activated directly when the ignition is turned on.
The pre-heating and post heating periods are dependent on coolant temperature.
If the parameter is in Off mode, pre-heating and post
heating must be activated manually via the ignition
lock or pre-heater button.
Alternative modes: Off or On
Preset mode: Off
Stop function
Lamp test
The CIU unit stop signal is energized during operations or stop.

Preset mode: Stop
This parameter determines if a lamp test is to be performed when the system is started.
Preset mode: On
Idling speed
Setting idle revolutions.
Min. value: 600 rpm
Max. value: 1200 rpm
Preset value: 900 rpm
7748542 10-2009
35
Adjustable parameters
NOTICE! Certain parameters require special authorization.
Regulator mode
Regulator gradient
Select if droop value is active.

Alternative modes: Off or No
Preset mode: No
Determines the droop value to be used (gradient)

Min. value: 10 Nm/revolution
Max. value: 128 Nm/revolution
Preset value: 25 Nm/revolution
Inverted regulator mode
Primary regulator mode
Select if droop value is to be active.

Alternative modes: No droop value or Variable
droop value
Preset mode: Fixed droop value

contact is closed.
Alternative modes: Isochronous or Droop value
Preset mode: Isochronous
Idling speed
Idle voltage (CIU)
Setting idle revolutions.

Min. value: 600 rpm
Max. value: 900 rpm
Preset value: 700 rpm
Throttle control input signal voltage to corresponding

idle at the CIU unit.
Min. value: 0.30 V
Max. value: 1.90 V
Voltage max. rpm (CIU)
Pre-heating for ignition
Throttle control input signal voltage to corresponding

full throttle at the CIU unit.
Min. value: 1.90 V
Max. value: 4.70 V
Selects if pre-heating is to be activated directly the

ignition is turned on. If the parameter is in Off mode,
pre-heating and post heating must be activated manually via the ignition lock or pre-heater button.
Preset mode: Off
Stop function
CIU stop function
Preset mode: Stop
The CIU unit stop signal is energized during Operations or Stop.

Preset mode: Stop
Lamp test
This parameter determines if a lamp test is to be performed when the system is started.
Preset mode: On
36
7748542 10-2009
Alarm limits
Alarm threshold, high oil temperature
A warning lamp is lit at this temperature.
Min. value: 120 C (248 F)
Preset value: 125 C (257 F)
Max. value: 130 C (266 F)
Alarm threshold, high coolant temperature
Overspeed limit
Percent above normal revolutions at which the overspeed warning is activated.
Min. value: 0 %
Preset value: 20 %
Max. value: 20 %
Alarm limits
Alarm threshold, high oil temperature
7748542 10-2009
Alarm threshold, high coolant temperature

37
Engine protection
Oil temperature
Determines whether engine protection is to be activated in respect of high oil temperature. A fault code
is registered and the engine is shut down.
Alternative modes: Yes or No
Preset mode: Yes
Oil pressure
Determines whether engine protection is to be activated in respect of low oil pressure. A fault code is
registered and the engine is shut down.
Preset mode: Yes
Coolant temperature
Determines whether engine protection is to be activated in respect of high coolant temperature. A fault
code is registered and the engine is shut down.
Preset mode: Yes
Piston cooling pressure

Determines whether engine protection is to be activated in respect of low piston cooling pressure. A fault
Preset mode: Yes
Coolant level
Determines whether engine protection is to be activated in respect of low coolant level. A fault code is
Preset mode: Yes
Crankcase pressure
Determines whether engine protection is to be activated in respect of high crankcase pressure. A fault
Preset mode: Yes
Charge air temperature

Determines whether engine protection is to be activated in respect of high charge air temperature. A fault
Preset mode: Yes
Overspeed warning shutdown

Determines whether engine protection is to be activated in respect of overspeed. A fault code is registered and the engine is shut down.
Preset mode: Yes
Charge pressure
Determines whether engine protection is to be activated in respect of high charge air pressure. A fault
Preset mode: Yes
38
7748542 10-2009
Engine protection
Oil temperature
Determines whether engine protection is to be activated in respect of high oil temperature. A fault code
is registered and the engine is shut down.
TAD1650VE: a fault code is registered and an orange
or red warning lamp is lit.
Preset mode: Yes
Coolant temperature
Determines whether engine protection is to be activated in respect of high coolant temperature. A fault
Preset mode: Yes
Coolant level
Determines whether engine protection is to be activated in respect of low coolant level. A fault code is
TAD1650VE: a fault code is registered and an orange
warning lamp is lit.
Preset mode: Yes
Charge air temperature
Determines whether engine protection is to be activated in respect of high charge air temperature. A fault
Preset mode: Yes
Oil pressure
Determines whether engine protection is to be activated in respect of low oil pressure. A fault code is
Preset mode: Yes
Piston cooling pressure
Determines whether engine protection is to be activated in respect of low piston cooling pressure. A fault
Preset mode: Yes
Crankcase pressure
Determines whether engine protection is to be activated in respect of high crankcase pressure. A fault
Preset mode: Yes
ECU temperature
Determines whether engine protection is to be activated in respect of high control unit temperature. A
fault code is registered and an orange or red warning
lamp is lit.
Charge pressure
Determines whether engine protection is to be activated in respect of high charge air pressure. A fault
Preset mode: Yes
7748542 10-2009
39
Control System Installation, Diagnostic Function
Diagnostic Function
The diagnostic function monitors and controls that the
EMS system functions normally. The diagnostic function has the following tasks:
Detecting and locating disturbances

Reporting detection of disturbances
Providing guidance when fault tracing
NOTICE! With the DCU:n it is possible choose the language that the inform-tion is presented in.
If the diagnostic function detects a disturbance in the
system, this is reported using fault codes via the instruments.
Both active (unrectified) and passive (rectified) faults
are stored in the control unit.
Refer to the Operation heading for reading fault
codes/fault messages.
All fault codes and fault messages are found in the fault
code list, with information about the reason, reaction
and measures to be taken. Refer to Fault Code Register.
NOTICE! All instruments are optional.
Effect on engine
Engines are affected differently, depending on the
severity of the fault discovered by the diagnostic function.
A fault message in the form of a fault code is always
generated when a malfunction is discovered by the
diagnostic function.
Engines are affected differently, depending on the
severity of the fault:
The engine is not affected

Engine goes to idle
Engine torque is restricted to a certain amount
Engine is stopped
40
7748542 10-2009
Active and Inactive Faults

Active faults
At the same time, the fault is stored in the control unit
memory. When the fault has been attended to and the
ignition is switched off and on again, the fault disappears as active.
Inactive faults
DCU the fault is indicated as passive
CIU the diagnostic lamp goes out
DU the fault message disappears (inactive

faults cannot be read out)
Easy Link the lamp on the alarm panel goes

out
text !! ENGINE WARNING !! shown on the display.
the diagnostic lamp starts to flash.
Easy Link instrument

- the relevant lamp on the alarm panel lights up
- after the diagnostic button has been pressed,
the fault code is shown as text on the tachometer
display.
DU (Display Unit)
Either WARNING! or ALARM STOP (a buzzer

sounds) will be shown on the display, depending
on the severity of the fault.
Fault codes can also be read off using the

VODIA tool. For instructions, see VODIA Users
Guide.
Operation
When a malfunction has occurred and the diagnostic
system has generated one or more fault codes, these
are read out differently depending on the equipment
used. Please refer to Fault code messages.
If the system indicates that a fault code has been
set:
1 Cut engine speed to idle, or shut the engine off.
2 For DCU/DU
Read the fault code from the display, please
refer to Reading fault codes via the DCU or
Reading fault codes via the DU.
For CIU
press the diagnostic button and read the fault
code, by observing the flashing of the diagnostic
lamp. Refer to Reading fault codes via the
diagnostic lamp, CIU.
Reading fault codes via the DU (Display Unit)

Depending on the severity of the fault the text, either
WARNING! or ALARM STOP (a buzzer sounds) will
be shown on the display
1 Press any button to come to the fault list. The
fault list shows operation hours and fault message.
2 Look up the fault code in Fault Code Register
and take the recommended measures.
3 Press on ACK to acknowledge the fault code.
The display background will change color (the
buzzer stops sounding).
4 Press on EXIT to leave the fault list.
3 Look up the fault code in the Fault Code Register chapter and take the recommended measures.
7748542 10-2009
41

Reading fault causes via the DCU (Display Control
Unit)
When a fault code is set, the following text is shown
on the display:
!! ENGINE WARNING !!
alternated withPress SEL for information.
Read the fault code as follows:
1 Press SEL-button to come to the fault list.
The fault list shows:
-Operation hours
-Fault message
-Active/inactive
2 Look up the fault code in theFault Code Register chapter and take the recommended measures.
Reading fault codes via an Easylink instrument

When the system has discovered a malfunction, this
is reported by the diagnostic lamp which starts to
flash.
1 Press the diagnostic button. The fault code is
shown as text on the tachometer display.
2 Look up the fault code in the Fault Code Register chapter and take the recommended measures.
3 When the fault has been rectified, the fault code
disappears from the display and the diagnostic
lamp goes out.
3 Press ESC-button to leave the fault list.

NOTICE! To enter the fault list when no fault code has
been set, press the SEL button and select Diagnostics from the menu.
Reading fault codes via the diagnostic lamp on

the instrument panel, CIU
When the system has discovered a malfunction, the
diagnostic lamp starts to flash. If the diagnostic button
is depressed and then released, a fault code is
flashed out.
The fault code consists of two groups of flashes, separated by a pause of two seconds. A fault code is
obtained by counting the number of flashes in each
group
Example:
paus
= Fault Code 2.4
The fault code is stored and can be read as long as
the malfunction remains. You can find information
about cause, reaction and actions in the Fault Code
Register chapter.
Read the fault code as follows:
Erasing fault codes

Fault codes must be erased by an authorized Volvo
Penta workshop by means of the VODIA tool.
1 Press the diagnostic button.

2 Release the diagnostic button and make a note
of the fault that is flashed out.
3 Repeat items 1-2. A new fault code is flashed ou
tif more are stored. Repeat until the first fault
code is repeated.
NOTICE! When the first fault code reoccurs, all the
fault codes have been read.
If the diagnostics button is depressed after the fault
has been corrected and the fault code deleted, the
code 1.1, No fault, will be shown.
42
7748542 10-2009
Control System Installation, Fault Code Register
Fault Code Register

CAUTION!
Read through the safety advice before starting any work.
The fault codes below comprise:
-
a fault text message displayed when a DCU or DU is installed.
a flash code, e.g. 5.4, read off from the diagnostics lamp; refer to Control System Installation page 40
a fault code, e.g. PID 45, read off from the VODIA tool.
For references to sleeves in electrical connectors, refer to System Information page 12.
No fault (Code 1.1)

Cause
There are no active faults.
Reaction
Remedy
Water in Fuel (Code 2.1, PID/SPN 97)

Cause
Water in fuel
Reaction
None
Remedy
Empty the primary fuel filter
Coolant Level (Code 2.2, PID/SPN 111)

Cause
Low coolant level
Reaction
Engine control module
reduces engine power
(unless the protection has
been shut off with the VODIA
diagnostic tool)
Remedy
Check the coolant level
Check coolant level monitor

function
Coolant Level Sensor (Code 2.3, PID/SPN 111)

Cause
Short circuit to positive (+)
Reaction
None
Fault in sensor
Remedy
Check that the coolant level
sensor cable is not damaged
Check coolant level sensor

function
Flywheel Speed Sensor (Code 2.4, SID 22/SPN 637)

Cause
No signal
Abnormal frequency
Intermittent signal from the

sensor
Fault in sensor
7748542 10-2009
Reaction
Engine is very difficult to start
and runs roughly when it
starts
Remedy
Check that the sensor connector is correctly installed
Check that the engine speed


sensor is correctly installed in
the flywheel housing
Check engine speed sensor

function
43
Camshaft Drive Speed Sensor (Code 2.5, SID21/SPN 636)

Cause
No signal
Abnormal frequency
Fault in sensor
Reaction
Engine takes longer to start
than normal. Engine runs normally when running
Remedy
sensor connector is correctly
installed


sensor is correctly installed in
the upper timing gear cover.
Check engine speed sensor

function.
Engine Speed (Code 2.6, PID/SPN 190)

Cause
Engine speed too high
Reaction
None
Remedy
After the engine has stopped,
look for the reason for the high
speed
Speed Potentiometer Connected to CIU (Code 2.8, PPID 132/SPN 91, 608,)
Cause
Shorted to plus (+) or minus
(-)
Reaction
Engine goes to idle
Speed feezes
Fault in sensor
Remedy
Check that the potentiometer
has been connected correctly
Check that the cable harness

to the potentiometer has not
been damaged
Check the potentiometer

function
Indicator for Water in Fuel (Code 2.9, PID/SPN 97)

Cause
Short circuit
Open circuit
Fault in indicator
Reaction
None
Remedy
Check the indicator cables for
breaks and short circuits
Check indicator function.

Change indicator as necessary
Oil Pressure Sensor (Code 3.1, PID/SPN 100)

Cause
Short circuit to positive (+) or
earth (ground) ()
44
Open circuit
Reaction
None
Remedy
Check that the oil pressure
Check that the oil pressure

sensor is correctly connected
7748542 10-2009
Boost Temperature Sensor (Code 3.2, PID/SPN 105)

Cause
earth (ground) ()
Reaction
None
Open circuit
Remedy
Check that the boost temperature sensor connector is correctly installed
Check that the boost temperature sensor cable is not damaged
Check that the boost temperature sensor is correctly

installed
Check boost temperature

sensor function
Coolant Temperature Sensor (Code 3.3, PID/SPN 110)

Cause
earth (ground) ()
Reaction
Preheating is also activated
when the engine is hot
Open circuit
Remedy
Check that the coolant temperature sensor connector is
correctly installed
Check that the coolant temperature sensor cable is not

damaged
Check that the coolant temperature sensor is correctly

installed
Check coolant temperature

sensor function
Boost Pressure Sensor (Code 3.4, PID/SPN 102/106)

Cause
earth (ground) ()
Open circuit
7748542 10-2009
Reaction
Engine smokes more than
normally during acceleration/
load increase
Remedy
Check that the boost pressure
installed


sensor is correctly installed
Check boost pressure sensor

function
45
Boost Pressure Sensor (Code 3.5, PID/SPN 106)

Cause
High charge pressure
Reaction
Engine power is reduced or
engine stops.
Action
Check that the charge air
pressure sensor connector is
correctly installed

pressure sensor cable is not
damaged

pressure sensor is correctly
installed
Check charge air temperature

sensor function
Fuel Pressure Sensor (Code 3.6, PID/SPN 94)

Cause
earth (ground) ().
Reaction
None
Open circuit.
Remedy
Check that the fuel pressure
installed.

sensor cable is not damaged.

sensor is correctly installed.
Check fuel pressure sensor

function.
Oil Temperature Sensor (Code 3.7, PID/SPN 175)

Cause
(-)
Reaction
None
Break
Remedy
to the oil temperature sensor
has not been damaged
Check that the oil temperature sensor has been connected correctly
Fuel Pressure (Code 3.8, PID/SPN 94)

Cause
Low supply pressure
Reaction
None
Remedy
Check if it is possible to build
up pressure with the hand
pump
Check the fuel filter
Check the fuel pre-filter
Battery Voltage, EMS (Code 3.9, PID/SPN 158)

Cause
Faulty alternator
46
Faulty battery, battery cables
Reaction
None
Remedy
Check the supply voltage
from the control unit
7748542 10-2009
Start output/Start motor relay (Code 4.6, PPID 3/ SPN 677)

Cause
(-)
Reaction
The engine cannot be started
Activated for too long
The engine starts immediately when ignition is turned

on
Remedy
Check that connections to the
ignition key/start panel have
not been damaged

to the ignition key/sart panel
Stop Input EMS (Code 4.8, PPID 6/SPN 970)

Cause
Short circuit to negative (-)
Open circuit
Reaction
Engine can only be stopped
with the auxiliarystop
Remedy
Check that the starter switch
connections are not damaged
Starter Input CIU (Code 5.2, PPID 4/SPN 520194)

Cause
Shorted to minus (-)
Activated for too long
Reaction
The engine cannot be started
The engine starts immediately when ignition is turned

on
Remedy
Check that connections to the
ignition key/start panel have
not been damaged

to the ignition key/start panel
Stop Input CIU (Code 5.3, PPID 6/SPN 52095)

Cause
Open circuit
Activated for too long time
Reaction
Engine can only be stopped
with the auxiliary stop (AUX
STOP) on engine
Remedy
Check that the starter switch
connections are not damaged
Engine stops. A fault code is

displayed for 40 seconds and
the engine can not be started
during this time. When a fault
code is active, the engine can
be started but not stopped
Check that the ignition switch

cable is not damaged
Preheating Relay (Code 5.4, PID 45/SPN 626)

Cause
earth (ground) ().
Open circuit.
Reaction
Preheating can not be activated.
Preheating is constantly connected.
Remedy
Check that the relay input
cable is not damaged.
Check relay function.
Air Filter Pressure (Code 5.5, PID/SPN 107)

Cause
Too large pressure drop
across filter
7748542 10-2009
Reaction
Less good response from
engine
Remedy
Check the air filter
47
Air Filter Sensor (Code 5.6, PID/SPN 107)

Cause
(-)
Reaction
None
Break
Remedy
Check that the air filter sensor
contact is correctly installed

to air filter sensor has not
been damaged
Check the air filter sensor

functionality
Oil Level (Code 5.7, PID/SPN 98)

Cause
Oil level to low
Reaction
None
Remedy
Check the oil level
Oil Temperature (Code 5.8, PID/SPN 175)

Cause
Oil temperature is too high
Reaction
The engine control module
limits engine output(unless
protection has been turned off
with thediagnosis tool
VODIA)
Remedy
Check the oil level
Check the oil temperature
Check the oil temperature

sensor function
Oil Level Sensor (Code 5.9, PID/SPN 98)

Cause
(-)
Reaction
None
Break
Remedy
to the oil level sensor has not
been damaged
Check the oil level sensor

function
Coolant Temperature (Code 6.1, PID/SPN 110)

Cause
Coolant temperature is too
high
Reaction
diagnostic tool)
Remedy
Check the charge air cooler

(cleanliness)
Check if there is air in the

cooling system
Check the pressure cap on

the expansion tank
Check coolant temperature

sensor function
Check thermostat function
Boost Temperature (Code 6.2, PID/SPN 105)

Cause
Boost temperature is too high
48
Reaction
diagnostic tool)
Remedy
Check the charge air cooler

(cleanliness)
Check boost temperature

sensor function
Check the function of the thermostat
7748542 10-2009
Data Link (CAN), CIU (Code 6.4, SID 231/SPN 639)

Cause
Faulty data link (CAN), , CIU
Reaction
Instruments and warning
lamps stop working
Remedy
Check that the 8-pin connector is not damaged
Check that the cables

between the CIU and the
engine management unit are
not damaged
Data Link (CAN), EMS 2 (Code 6.5, SID 231/SPN 639/2017/PSID 201)
Cause
Internal fault in control module
Reaction
Engine not operating: engine
can not be started. Engine
operating: engine idles and
can only be stopped with the
auxiliary stop (AUX-stop)
Remedy

between the CIU and the
engine management unit are
not damaged
Check that sleeves 11 and 12

in the connector on the CIU
are not damaged
Oil Pressure (Code 6.6, PID/SPN 100)

Cause
Oil pressure is too low
Reaction
diagnostic tool)
Remedy
Check oil level
Check that the air filter is not

blocked
Check system pressure

valves and safety valves in
the oil system
Check oil pressure sensor

function
Piston Cooling Pressure (Code 6.7, PPID 8/SPN 520192)

Cause
Piston cooling pressure is too
low
Reaction
Engine stopped
Remedy
Check that the oil pressure in
the engine exceeds175 kPa
(25.4 psi)
Piston Cooling Pressure Sensor (Code 6.8, PPID 8/SPN 520192)

Cause
(-)
Break
7748542 10-2009
Reaction
None
Remedy
Check that the piston cooling
pressure sensor contact is
correctly installed

to the piston cooling pressure
sensor has not been damaged
Check the piston cooling

pressure sensor functionality
49
Battery Voltage, CIU (Code 6.9, PID/SPN 158)

Cause
Faulty alternator
Faulty battery, battery cables
Reaction
Problems in engine starting
Remedy
Check the supply voltage
from the control unit
Check the batteries
Check the alternator
Check the 8-pin contact
SInjector, Cylinder #1 (Code 7.1, SID 1/SPN 651)

Cause
Electrical fault
Faulty compression or injector
Reaction
Engine runs on 5 cylinders
Abnormal sound
Reduced performance
Remedy
Check that the injector cables
are not damaged
Check that the injector connections are not damaged
Check fuel supply pressure
Check the valve clearance
Do a compression test and

check cylinder #1
Injector, Cylinder #2 (Code 7.2, SID 2/SPN 652)

Cause
Electrical fault
Reaction
Abnormal sound
Reduced performance
Remedy
are not damaged

check cylinder #2

Cause
Electrical fault
50
Reaction
Abnormal sound
Reduced performance
Remedy
are not damaged

check cylinder #3
7748542 10-2009

Cause
Electrical fault
Reaction
Abnormal sound
Reduced performance
Remedy
are not damaged

check cylinder #4

Cause
Electrical fault
Reaction
Abnormal sound
Reduced performance
Remedy
are not damaged

check cylinder #5

Cause
Electrical fault
Reaction
Abnormal sound
Reduced performance
Remedy
are not damaged

check cylinder #6
Crankcase Ventilation Pressure (Code 7.7, PID/SPN 153)

Cause
Crankcase ventilation pressure too high
7748542 10-2009
Reaction
The engine is shut down (if
the protection has notbeen
shut off by the parameter tool)
Remedy
Check whether the crankcase
ventilation is blocked
Check whether cylinder liners, pistons or piston rings are

worn or damaged
51
Crankcase Ventilation Pressure Sensor (Code 7.8, PID/SPN 153)

Cause
(-)
Reaction
None
Break
Remedy
Check that the crankcase
ventilation pressure sensor
contact is correctly installed

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
None
Break
Remedy
Check that the air temperature sensor contact is correctly installed

to the air temperature sensor
Check that the air temperature sensor is correctly installed
Check the air temperature

sensor functionality
Injection Pressure (Code 8.3, PID/SPN 164)

Cause
Fault in fuel supply
Fault in fuel pump
Fault in harness
Fault in sensor
Reaction
Warning lamp lights up
Control unit reduces engine

power
Remedy
Check harness
Check sensor
Check fuel filter
Check fuel pump
Injection Pressure, Regulator (Code 8.3, SID 42/SPN 679)

Cause
Faulty cables
Faulty actuator
Fault in MPROP
Reaction
power
Remedy
Contact an authorized Volvo
Penta workshop
Pressure in Distribution Manifold (Code 8.3, PSID 96/SPN 1239)

Cause
Leakage in the high pressure
fuel system
52
Reaction
power
Remedy
Penta workshop
Leakage in the high pressure

supply pipe to the injector
7748542 10-2009
Pressure Valve (Code 8.3, PSID 97/SPN 679)

Cause
Leakage in the PRV (Pressure Release Valve)
The PRV stuck closed
The PRV stuck open
Reaction
power
Remedy
Penta workshop
ECU Temperature (Code 8.4, PPID 55/SPN 1136)

Cause
Control unit too hot, incorrect
assembly
Reaction
None
Remedy
Check the control unit installation. Recommended ambient temperature is 50C
(122F)
Electrical fault, damaged sensor

TAD1353GE
Internal EGR (Code 8.5, PPID 19/SPN 2791)

Cause
Fault in cable harness (boost
pressure sensor)
Reaction
Mechanical fault on the IEGR
Remedy
Check cable harness (boost
pressure sensor)
Check the IEGR
Contact a Volvo Penta

authorized workshop
Preheating Sensor (Code 8.6, SID 70/SPN 729)

Cause
Fault in cable harness
Fault in preheating relay
Reaction
Preheating can not be activated
Remedy
Check the cable harness
Check the preheating relay
Faulty data link (J1587) (Code 9.2, SID 250/SPN 608)

Cause
Faulty data link
Reaction
None
Remedy

between the CIU/DCU and
the engine management unit
are not damaged
Power Supply to Sensor (Code 9.3, SID 211/232, SPN 1079/1080)

Cause
Shortcut
Fault in sensor
7748542 10-2009
Reaction
Faulty values in oil pressure
and boost pressure sensors
Fault code for oil pressureand boost pressure sensor
Low engine output
The instrument shows zero oil

pressure and boost pressure
Remedy
to oil pressure and boost
pressure sensor has not been
damaged
Check oil pressure and boost

pressure sensors
53
Data Set Memory EEPROM, CIU (Code 9.8, SID 253/SPN 630)
Cause
Reaction
Engine does not start
Remedy
Re-program the control module.
Programming faulty
Fault in Control Unit, CIU (Code 9.8, SID 254/SPN 629)

Cause
Faulty EEPROM, CIU
Reaction
CIU returns to factory setting
Faulty flash memory, CIU
Engine goes to idle
Fault in control module, CIU
Engine can not be started
Remedy
Re- program the unit
Memory Fault EMS (Code 9.9, SID 240/SPN 628)

Cause
Memory fault in engine management system
Reaction
Engine might not start
Remedy
Re-program the unit
Data Set Memory EEPROM, EMS (Code 9.9, SID 253/SPN 630)
Cause
Reaction
Remedy
Re-program the control module. If the fault remains,
change the control module
Control Module EMS (Code 9.9, SID 254/SPN 629)

Cause
Reaction
Engine misfires
Remedy
Change engine control unit
Wastegate (SID 32/SPN 1188)

Cause
negative (-)
Open circuit
Wastegate damaged
mechanically
Reaction
Engine control unit limits

engine power
Remedy
Check that the wastegate
connector is properly
mounted
Check that the wiring to the

wastegate is not damaged
Check that the wastegate is

correctly mounted
Check the wastegate
Fan, rpm sensor (PID 26/SPN 975)

Cause
Open circuit
54
Reaction
Remedy
Check that the fan actuator is
properly mounted

fan actuator is not damaged

correctly mounted
Check the fan actuator
7748542 10-2009
Fan actuator (SID 33/SPN 975)

Cause
negative (-)
Reaction
Remedy
properly mounted
Open circuit
Fan actuator damaged

mechanically

fan actuator is not damaged

correctly mounted
Check the fan actuator
7748542 10-2009
55
Alphabetical index
Adjustable parameters.................................... 35, 36
Alarm limits.............................................................. 37
CIU.................................................................... 20, 23
Connection.............................................................. 17
Connection of special tool VODIA........................... 34
Control System Installation...................................... 17
DCU......................................................................... 26
Diagnostic Function................................................. 40
EMS........................................................................... 5
Engine protection.............................................. 38, 39
Fault Code Register.............................................. 43
General................................................................... 17
In- and out signals................................................... 8
Installation Tools and Documentation....................... 4
Instruments................................................................ 9
Instruments.............................................................. 30
Location of Sensors.............................................. 10
Other Special Equipment........................................ 4
Parameter Setting.................................................. 34
Power supply........................................................... 18
Rpm-potentiometer............................................... 28
Safety Information................................................... 2
Special Tools............................................................. 4
Synchronizing Engine Speed.................................. 33
System Information................................................... 5
Warning and Indication Lamps............................ 29
Wiring Diagram........................................................ 12
7748542 10-2009
57
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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.
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AB Volvo Penta
Teknisk Information
Avd. 42200
SE-405 08 Gteborg
Sweden
7748542 English 10-2009

VOLVO 7748542 - US - Installation EMS 2 - D13

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VOLVO 7748542 - US - Installation EMS 2 - D13

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Installation

TAD1341GE, TAD1342GE, TAD1343GE, TAD1344GE

This installation manual contains information for

Installation Tools and Documentation, Special Tools

Installation Tools and Documentation

3838619 VODIA, diagnostic

Other Special Equipment

AMP 726 519

AMP 825 514

AMP 539 968

AMP 726 519

AMP 929 039

AMP 238 635

GHW 50000 017 586

System Information, EMS

CAN (Controller Area Network)

System Information, EMS

CIU (Control Interface Unit)

System Information, EMS

Calculating fuel quantity

Requested engine speed

Boost air pressure

System Information, EMS

In- and out signals

System Information, EMS

System Information, EMS

8. Fan, rpm sensor

2. Combined charge air pressure and charge air

9. Under-pressure sensor, air filter

3. Oil pressure sensor

10. Coolant level sensor, in the expansion tank

7. Fuel pressure sensor

MAIN RELAY HOLD

System Information, EMS

System Information, EMS

11 Connector (not used)

System Information, EMS

CIU (Control Interface Unit)

System Information, EMS

Key switch, operating current (15+)

Alarm, low coolant level

System Information, EMS

DCU (Display Control Unit)

Control System Installation, Connection

Control System Installation

Secure the connecting cable between the engine

and instrument panel with clamps. Bear in mind that

The cables must not be run close by hot engine

components or close to any other heat source.

As far as possible, avoid splices in the system wir-

ing. The cables and any splices must be accessible

NOTICE! Connectors must be assembled dry, they

Control System Installation, Connection

Control System Installation, Connection

Battery cable cross-sectional area

Control System Installation, Connection

A 8-pin Deutsch connector, from wire harness to engine

D For the connection cable, refer to the Instruments page 30 section.

Control System Installation, Connection

Control System Installation, Connection

Control System Installation, Connection

A 8-pin Deutsch connector, from wire harness to engine

D For the connection cable, refer to the Instruments page 30 section.