Workshop Manual: (Group 23) EDC 4

Workshop Manual
(Group 23) EDC 4
TD420VE, TAD420VE, TD520GE, TAD520GE,

TAD520VE, TAD620VE, TD720GE, TAD720GE,
TAD720VE, TAD721GE, TAD721VE,
TAD722GE, TAD722VE
Workshop manual
EDC 4
TD420VE, TAD420VE, TD520GE, TAD520GE,
TAD520VE, TAD620VE, TD720GE, TAD720GE,
TAD720VE, TAD721GE, TAD721VE, TAD722GE,
TAD722VE
Contents
Safety information ................................................. 2 Repair instructions .............................................. 26
Introduction .......................................................... 2 Working on the EDC4 ......................................... 26
Control unit, change ........................................... 27
General information .............................................. 5 Speed regulator, change .................................... 27
About the workshop manual ................................. 5 Starting with auxiliary batteries .......................... 28
Spare parts .......................................................... 5
Certified engines .................................................. 5 Function check .................................................... 29
Diagnostic function with program for PC ............ 29
Repair instructions ................................................ 6
Our common responsibility ................................... 6 Fault tracing ........................................................ 30
Tightening torque ................................................. 6 Symptoms and possible causes ........................ 30
Torque-angle tightening ........................................ 7
Lock nuts ............................................................. 7 Diagnostic function ............................................. 31
Strength classes .................................................. 7 Diagnostic function, tasks .................................. 31
Sealants .............................................................. 7 Malfunction message ......................................... 31
Fault tracing guide ............................................. 31
Engine signs ......................................................... 8 Effect on engine ................................................. 31
Location of engine signs ...................................... 8 Operation ........................................................... 31
Special tools ......................................................... 9 Fault codes .......................................................... 33
Technical data ..................................................... 10 Electrical fault finding ........................................ 39

General .............................................................. 39
Design and function ............................................ 13 Function checking of cables and connectors ...... 39
System description, EDC 4 ................................ 13 Fault tracing of cables and connectors ............... 40
Other functions .................................................. 14 Joining electrical cables for multi-connector ....... 41
Component description ...................................... 16 Inspection/fault tracing of components ............... 42
Component location ........................................... 20 Fault tracing the starter motor ............................ 45
Fault tracing the alternator ................................. 46
Limit values ......................................................... 21
Electrical system ................................................. 53
Parameter setting ................................................ 22 Important information about electrical system .... 53
Adjustable parameters ....................................... 22 Wiring diagram ................................................... 54
Read-only parameters ........................................ 24
Fine adjustment, engine speed regulator ............ 24
1
Group 23 EDC 4 Safety information
Safety information
Make sure that the warning or information labels
Introduction on the product are always clearly visible. Re-
The workshop manual contains descriptions and repair place labels which have been damaged or paint-
instructions for products or product versions noted in ed over.
the table of contents, supplied by Volvo Penta. Make
sure that you use the correct workshop literature. Never start an engine without the air filter in
place. The rotating compressor turbine in the
Read the available safety information, General Infor-
turbocharger can cause severe injury. Foreign
mation and Repair Instructions in the workshop bodies in the inlet pipe can also cause severe
manual before you start to do any service work. mechanical damage.
Important Never use start spray or similar products as a

starting aid. Explosions could occur in the inlet
The following special warning signs are used in the manifold. Danger of personal injury.
workshop manual and on the engine.
WARNING! Warns for the risk of personal injury, Only start the engine in a well- ventilated area.
major damage to product or property, or serious When operated in a confined space, exhaust
malfunctions if the instruction is ignored. fumes and crankcase gases must be ventilated
from the engine bay or workshop area.
IMPORTANT! Is used to call attention to things
which could cause damage or malfunctions to Avoid opening the coolant filling cap when the
product or property. engine is hot. Steam or hot coolant can spray
out at the same time as the pressure which has
NOTE! Is used to call attention to important informa- built up is lost. Open the filler cap carefully if
tion, to facilitate work processes or operation. necessary, and release the excess pressure in
To give you a perspective on the risks which always the cooling system. Be extremely careful if a
tap, plug or coolant hose has to be removed
need to be observed and precautions which always
from a hot engine. Steam or hot coolant can
have to be taken, we have noted them below.
stream out in an unexpected direction.
Make it impossible to start the engine by cutting Hot oil can cause burns. Avoid skin contact with
system current with the main switch(es) and hot oil. Make sure that the lubrication oil system
lock it (them) in the off position before starting is de- pressurized before doing any work on it.
service work. Fix a warning sign by the control Never start or run the engine with the oil filler
station. cap removed, because of the risk of oil spillage.
All service work should normally be done on a Stop the engine before doing any work on the
stationary engine. Some work, such as adjust- cooling system.
ments, need the engine to be running, however.
Going close to a running engine is a safety risk.
Remember that loose clothes, long hair etc. can
catch on rotating components and cause severe
injury.
If work is done adjacent to a running engine, a

careless movement or a dropped tool can lead
to personal injury in the worst case. Be careful
with hot surfaces (exhaust pipes, turbos, charge
air pipes, starting heaters etc.) and hot fluids in
pipes and hoses on an engine which is running
or which has just stopped. Re- install all guards
which have been removed during service work,
before re- starting the engine.
2
If other equipment connected to the engine has Most chemicals intended for the product, such
altered its centre of gravity, special lifting devis- as engine and transmission oils, glycol, petrol
es may be needed to obtain the correct balance (gasoline) and diesel oil, or chemicals for work-
and safe handling. shop use, such as degreasers, paints and sol-
vents are hazardous. Read the instruction on
Never do any work on an engine which just the packages carefully! Always observe the
hangs from a lifting devise. safety advice, e.g. use of breathing protection,
goggles, gloves etc. Make sure that other per-
Never work alone when heavy components are sonnel are not inadvertently exposed to hazard-
to be dismantled, even when safe lifting devises ous substances, such as via the air they
such as lockable blocks & tackle are used. breathe. Ensure good ventilation. Handle used
Even when lifting devises are used, two people and surplus chemicals in the prescribed manner.
are needed in most cases. One who operates
the lifting devise and other who makes sure that Be very careful when searching for leaks in the
components move freely and are not damaged fuel system and testing fuel injectors. Use gog-
during lifting. gles. The jet which comes from a fuel injector
has very high pressure and considerable pene-
Always make sure that there is enough space tration ability. Fuel can force its way deep into
for disassembly where you are working, with no body tissue and cause severe injury. Risk of
risk for personal or material damage. blood poisoning (septicemia).
WARNING! Components in the electrical and All fuels, and many chemicals, are flammable.
fuel systems on Volvo Penta products have Make sure that open flames or sparks can not
been designed to minimize the risks of explo- set them alight. Petrol (gasoline), some thinners
sion and fire. The engine must not be operated and hydrogen gas from batteries are extremely
in environments with adjacent explosive media. flammable and explosive when mixed with air in
the correct ratio. Do not smoke! Provide good
Only use the fuels recommended by Volvo Pen- ventilation and take the necessary precautions
ta. Please refer to the instruction book. The use before you start welding or grinding work in the
of fuel of inferior quality can damage the engine. vicinity. Always have a fire extinguisher easily
In a diesel engine, poor fuel can make the en- available near the workplace.
gine over- rev, entailing a strong risk of personal
injury and machinery damage. Poor fuel can Make sure that oil and fuel soaked rags, and
also lead to higher maintenance costs. used fuel and oil filters are disposed of in a safe
manner. Oil soaked rags can self-ignite in cer-
Remember the following when washing with a tain circumstances. Used fuel and oil filters are
high pressure washer: Never aim the water jet at polluting waste and must be handed to an ap-
seals, rubber hoses, electrical components or proved waste management facility for destruc-
the radiator. tion, together with used lubrication oil, contami-
nated fuel, paint residue, solvents, degreasers
Always use goggles when doing any work where and wash residue.
there is any risk of splinters, grinding sparks,
acid splash or other chemicals. Your eyes are Batteries must never be exposed to open
extremely sensitive, injury could cause blind- flames or electric sparks. Do not smoke close
ness! to the batteries. The batteries generate hydro-
gen gas when charged, which forms an explo-
Avoid skin contact with oil! Long- term or repeat- sive gas when mixed with air. This gas is very
ed skin contact with oil can injure your skin. The flammable and highly explosive. A spark, which
consequence is irritation, dry skin, eczema and can be formed if the batteries are wrongly con-
other skin disorders. Used oil is more hazardous nected, is enough to make a battery explode
to health than new oil. Use protective gloves and cause damage. Do not move the connec-
and avoid oil-soaked clothes and rags. Wash tions when you attempt to start the engine (risk
regularly, especially before meals. Use special of arcing), and do not stand and lean over one of
skin cream to avoid drying and facilitate skin the batteries.
cleaning.
3
Never mix up the battery positive and negative The clutch must be adjusted with the engine
poles when the batteries are installed. If the bat- shut off.
teries are wrongly connected, this can cause se-
vere damage to the electrical equipment. Please The existing lugs on the engine should be used
check the wiring diagram! for lifting the engine/gearbox etc. Always check
that the lifting devices are in good condition and
Always use goggles when charging and handling that they have the correct capacity for the lift
batteries. Battery electrolyte contains highly cor- (the weight of the engine plus the gearbox and
rosive sulfuric acid. If this comes into contact extra equipment if installed).
with your skin, wash at once with soap and a lot
of water. If you get battery acid in your eyes, The engine should be lifted with a customized or
flush at once with a lot of cold water, and get adjustable lifting boom for safe handling and to
medical assistance at once. avoid damaging components on top of the en-
gine. All chains or cables must be parallel to
Stop the engine and cut the system current with each other and should be as square as possible
the main switch(es) before doing any work on to the top of the engine.
the electrical system.
4
Group 23 EDC 4 General information
General information
About the workshop manual Certified engines

This workshop manual contains descriptions and re- The manufacturer certifies that both new engines and
pair instructions for the standard versions of following those in use, which are certified for national or re-
engines: TD420VE, TAD420VE, TD520GE, gional legislation, comply with the environmental re-
TAD520GE, TAD520VE, TAD620VE, TD720GE, quirements Each product must correspond with the
TAD720GE, TAD721GE, TAD720VE, TAD721VE, unit used for certification. The following requirements
TAD722GE and TAD722VE for service and spare parts must be complied with, for
The workshop manual can illustrate tasks done on Volvo Penta as a manufacturer to be responsible for
any of the engines noted above. This means that the ensuring that engines in use comply with the stipu-
illustrations and photographs which clarify certain de- lated environmental requirements:
tails might not entirely correspond. The repair meth-
ods are similar in all important respects, however. The • Maintenance and service intervals recommended
by Volvo Penta must be complied with.
engine designation and number are noted on the type
plate. Please refer to the “Engine signs” chapter.
The engine designation and number must always be
given in all correspondence about an engine.
• Only Volvo Penta Original Spares, intended for
the certified engine variant, may be used.
The workshop manual has been primarily prepared for
Volvo Penta service workshops and their qualified per-
sonnel. This assumes that people who use the • Service which includes injection pumps, pump
settings or unit injectors must always be done by
manual have basic skills and can do the tasks of a
an authorized Volvo Penta workshop.
mechanical or electrical nature associated with the
trade.
Volvo Penta constantly improves its products, so we • The engine must not be converted or modified in
reserve the right to make modifications without prior any way, except for the accessories and service
notification. All information in this manual is based on kits which Volvo Penta has approved for the en-
product data which was available up to the date on gine.
which the manual was printed. Any material changes
introduced into the product or service methods after
this date are notified by means of Service Bulletins.
• Installation changes to the exhaust pipe and the
engine bay air inlet ducts (ventilation ducts) must
not be done without further discussion, since this
could affect exhaust emissions. No seals may be
Spare parts broken by unauthorized personnel.
Spare parts for electrical and fuel systems are subject

to various national safety requirements. Volvo Penta IMPORTANT! When spare parts are needed,
Original Spares comply with these requirements. No use only Volvo Penta Original Spares.
damage whatever, occasioned by use of non-original
The use of non-original spares means that
Volvo Penta spares for the product, will be compen-
Volvo Penta ceases to be responsible for en-
sated by the warranty offered by Volvo Penta.
suring that the engine corresponds with the
certified version.
Damage, injury and/or costs of whatever nature,

which arise due to the use of non-original Volvo
Penta spares for the product in question will not
be compensated by Volvo Penta.
5
Group 23 EDC 4 Repair instructions
Repair instructions
The work methods described in the workshop manual Our common responsibility
apply to work in a workshop environment. For this rea-
son, the engine is lifted out and mounted on an engine Each engine consists of a large number of collaborat-
support. Renovation work which does not need the ening systems and components. Any deviation of a
gine to be lifted out can be done in situ, with the same component from its technical specification can dra-
work methods, unless otherwise specified. matically increase the environmental impact of an oth-
erwise good engine. For this reason, it is extremely
important that specified wear tolerances are kept to,
Please refer to the “Safety information” chapter, where that systems with adjustment facilities are correctly
the meaning of the warning signs used in the Work- adjusted and that Volvo Penta Original Spares are
shop Manual are explained in detail. used for the engine. The times noted in the engine
maintenance schedule must be observed.
WARNING!
Some systems, such as components in the fuel sys-
tem, may require special competence and special test
IMPORTANT! equipment. For environmental reasons etc., some
components are sealed at the factory. It is only per-
missible to work on sealed components if you are au-
thorized to do such work.
NOTE!
Remember that most chemical products damage the
are not comprehensive in any way, since we can not
environment if they are incorrectly used. Volvo Penta
of course foresee everything, because service work is
recommends the use of biodegradable degreasers
done in highly varying circumstances. For this reason,
whenever engine components are de-greased, unless
all we can do is to point out the risks which we believe
otherwise specified in the workshop manual. Be care-
could occur due to incorrect work in a well-equipped
ful to ensure that oils, wash residue etc. are proc-
workshop, using work methods and tools tested by
essed for destruction, and are not inadvertently dis-
us.
charged to the environment.
In the workshop manual, all tasks for which there are
Volvo Penta special tools, are done using these tools.
Special tools are specially prepared to permit the saf-
est and most rational work methods possible. For this Tightening torque
reason, it is the responsibility of the person who uses
other tools or other work methods than those recom- The tightening torques for vital fasteners, which
mended by us, to ensure that there is no risk of per- should be tightened with a torque wrench, are listed in
sonal injury or material damage, and that they can not “Technical Data”, and are noted in the task descrip-
cause any malfunctions. tions in the manual. All torque specifications apply to
clean screws, screw heads and mating faces. The
In some cases, special safety regulations and user in- torque specifications apply to lightly oiled or clean
structions are available for the tools and chemicals screws. If lubricants, locking fluids or sealants are
mentioned in the workshop manual. These rules must needed on a fastener, the type of preparation to be
always be observed, so there are no special instruc- used will be noted in the job description and in “Tight-
tions about this in the workshop manual. ening Torques”. Where a particular torque value is not
The majority of risks can be prevented by taking cer- specified for any fastener, the general tightening tor-
tain elementary precautions and using common ques in the table below shall apply. The torque specifi-
sense. A clean workplace and a clean engine elimi- cation is a target value and the fastener does not
nate many risks of both personal injury and malfunc- need to be tightened with a torque wrench.
tion.
Above all, when work on fuel systems, lubrication Dimension Tightening torque
systems, inlet systems, turbocharger, bearing caps
and seals is done, it is extremely important that no Nm lbf.ft.
dirt or other kinds of foreign particles are able to get M5 6 4.4
in, since this would otherwise cause malfunctions or M6 10 7.4
shortened repair life.
M8 25 18.4
M10 50 36.9
M12 80 59.0
M14 140 103.3
6
Torque-angle tightening Sealants

In torque/angle tightening, the fastener is tightened to Several different types of sealant and locking fluids
the specified torque, and tightening then continues are used on the engine. The properties of the sealants
through a pre-determined angle. Example: for 90° an- differ, and they are intended for different strengths of
gle tightening, the fastener is turned a further 1/4 turn fastener, temperature, resistance to oil and other
in one sequence, after the specified tightening torque chemicals, and for the different materials and gap
has been achieved. thicknesses found in the engine.
It is therefore important that the correct types of seal-
ant and locking fluids are used on the fasteners where
needed, to give a fully acceptable service result.
Lock nuts
In the workshop manual, the relevant chapters contain
Disassembled locknuts shall not be re-used, they notes on the preparations used in our engine produc-
shall be replaced by new ones, since the locking prop- tion.
erties are impaired or lost when the nut is used sever-
In service work, equivalent preparations of the same
al times. On locknuts with plastic inserts, such as Ny-
make, or other makes of preparations with directly
lock®, the tightening torque specified in the table
corresponding properties shall be used.
must be reduced if the Nylock® nut has the same nut
height as a standard fully metallic hexagonal nut. Re- When sealants and locking fluids are used, it is impor-
duce the tightening torque by 25% if the screw dimen- tant that the surfaces are free from oil, grease, paint,
sion is 8 mm (0.3") or greater. On Nylock ® nuts with rust-protection and remains of old sealants. Always
higher nut height, where the fully metallic thread is as observe the manufacturer’s instructions about temper-
high as on a standard hexagonal nut, use the tighten- atures of use, hardening times and other instructions
ing torques in the table. for use of the product.
Two basic types of preparation are used on the en-
gine, characteristics are as follows:
Strength classes 1. RTV preparations (Room Temperature Vulcanizing).
These are mostly used together with gaskets, such as
Screws and nuts are sub-divided into different for sealing gasket joints, or are brushed on gaskets.
strength classes. The classification is shown by a RTV preparations are fully visible when the compo-
marking on the screw head. Markings of a higher nent has been disassembled; old RTV compound
number indicate stronger material. For example, a must be removed before the joint is sealed again.
screw marked 10-9 is stronger than one marked 8-8. The following preparations are RTV types: Loctite®
For this reason, it is important when fasteners are dis- 574, Volvo Penta 840879-1, Permatex® No. 3, Volvo
mantled, that the screws are put back in the correct Penta 1161099-5, Permatex ® No 77. Remove old
places when they are re-installed. When you change sealant with denatured alcohol in each case.
screws, please check the spare parts catalogue to en-
sure that the correct versions are obtained. 2. Anaerobic preparations. These preparations harden
in the absence of air. These preparations are used
when two solid components, such as two cast compo-
nents, are fitted together without a gasket. Common
uses are also to lock and seal plugs, stud threads,
taps, oil pressure monitors etc. Hardened anaerobic
preparations are glassy and for this reason, the prepa-
rations are colored to make them visible. Hardened
anaerobic preparations are highly resistant to sol-
vents, and old compound can not be removed. On re-
installation, degrease carefully and then apply new
sealant.
The following preparations are anaerobic: Loctite ®
572 (white), Loctite ® 241 (blue).
Note. Loctite ® is a registered trademark of the Loctite Corpora-

tion.
Permatex ® is a registered trademark of the Permatex Corpora-
tion.
7
Group 23 EDC 4 General
Engine signs
Location of engine signs
The engines are supplied with two engine signs, of
which one is installed on the right side of the engine
block.
Engine plate
1. Engine model 8. Indication of standard and/or specification
2. Engine specification number 9. ISO 3046 , Air temperature in °C (°F)
3. Engine series number (10 digits) 10. ISO 3046, Altitude above mean sea level in me-
4. Engine power, peak, without fan ters
5. Engine speed 11. Unit injector code (EP code)
6. Injection advance and type of camshaft 12. Piston class
7. Manufacturer’s identification code 13. Extra information
8
Group 23 EDC 4 Tools
Special tools
The following special tools are used in work on engines. Special tools can be ordered from Volvo Penta under the
part numbers given below.
999 9324 951 0060 951 2636
999 8482 3838619
Tools Designation – use 999 8482 Template, connector

999 9324 Cable terminal pliers, repair 951 2636 Pin tool, connector
951 0060 Multimeter, fault tracing/checking 1078054 Repair kit (not illustrated)
885675 Adapter (not illustrated) 3838619 VODIA
Other special equipment

The tools below are intended for use in work on the cable harnesses of the engine. The tools are not included in
Volvo Penta’s range, they must be ordered from a local AMP or Deutsch dealer. If you experience problems in
contacting a dealer, please contact Volvo Penta Quality Action Center for advice.
HDT-48-00 0411-310-1605 AMP 726 534 AMP 726 519
AMP 825 514 AMP 725 938 AMP 825 582
Deutsch connectors Blades and sockets 3.5 mm

HDT-48-00 Terminal crimping pliers 725 938-0 Dissasembly tool
0411-310-1605 Dissasembly tool 825 582-2 Terminal crimping pliers
JPT connector (25-pin EDC 4) 4.8 mm and 6.3 mm cable clamps. Tongues and
726 534-1 Dissasembly tool 1.6 mm pin width socket terminals
726 519-1 Dissasembly tool 2.8 mm pin width 825 514-1 Terminal crimping pliers
825 514-1 Terminal crimping pliers AMP Connector (25-pin round)

872 070-1 Dissasembly tool (not illustrated)
734 289-2 Terminal crimping pliers (not illustrated)
9
Group 23 EDC 4 Technical data
Technical data
Control unit
Voltage .................................................................. 24 V or 12 V (engine can be started from 6 V)
Connector .............................................................. 2 x 25-pin (AMP)
Max cable length .................................................... 5 m (16,4 ft)
Working range, temperature ................................... -40 °C (-40.0°F) to +85 °C (185.0°F)
Current drain (incl. actuator) ................................... <9 A, <11.5 A for 60 s (12 A fuse)
Weight ................................................................... 1.6 kg (3.5 lb)
Size (L x W x H) .................................................... 231 x 204 x 62 mm (9 x 8 x 2.4”)
Relative humidity ................................................... < 98% (at 55 °C (131.0°F))
Protection class ..................................................... IP 66k, IP X7, IP X9k to DIN40050
Impact tolerance .................................................... < 50 g (0,1 lb)
Vibration ................................................................ < 1.5 mm (0.06") (at 10 – 20 Hz)
< 180 mm/s (7.01" /s) (at 21 – 63 Hz)
< 7 g (at 64 – 2000 Hz)
Housing .................................................................. Cast, untreated aluminum
Diagnostic interface ............................................... Serial interface SAE J1708
Computer interface ................................................. CAN-Bus with ISO/DIS 11989, SAE J1939 protocol
Electromagnetic comparability ............................... Radiated interference 95/54/EWG
Interference immunity up to 100 V/m ISO 11452-2, ISO 7637,
TR 10605
Load dumping ........................................................ U < 60 V
Actuator
Connector .............................................................. 5 pin
Resistance, control solenoid .................................. app. 1.3 Ω
Resistance, measurement solenoid ....................... app. 25.4 Ω
Resistance, reference solenoid .............................. app. 25.3 Ω
Inductance, measurement solenoid ........................ app. 21.5 mH (stop position)
app. 8.1 mH (full throttle position)
Inductance, reference solenoid .............................. app. 13.3 mH (constant)
Speed sensor, camshaft

Connector .............................................................. 2 pin
Working range, engine speed ................................. 30 rpm to 4500 rpm
Resistance ............................................................. 336 W ± 34 W at 23 °C
Inductance ............................................................. 128.8 mH ± 13mH at 1kHz and 23 °C (73,4 °F)
Lowest voltage (û) .................................................. 150mV peak to peak at 2 mm (0.08") air gap and 30 rpm
Type ...................................................................... Inductive sensor
Max. tightening torque ............................................ 9 Nm (6.6 lbf-ft)
10
Coolant temperature sensor

Connector .............................................................. 2 pin
Rated voltage ......................................................... 5 ± 0.15 VDC
Characteristic .......................................................... -40 °C (-40.0°F) 45313 Ω
0 °C (32.0°F) 5896 Ω
23 °C (73.4°F) 2057 Ω
60 °C (140.0°F) 596 Ω
100 °C (212.0°F) 186 Ω
140 °C (284.0°F) 71 Ω
Type ...................................................................... NTC* (Negative Temperature Coefficient)
Max. tightening torque ............................................ 20 - 24 Nm (14.7-17.7 lbf-ft)
Charge pressure sensor, 3 pin

Voltage .................................................................. 5 V ± 0.25 VDC
Connector .............................................................. 3 pin
Working range, pressure: ....................................... 50 - 400 kPa (7-58.0 psi)
Pressure signal ...................................................... 0.5 – 4.5 VDC
Type ...................................................................... Linear
Charge pressure sensor, 4 pin

Voltage .................................................................. 5 VDC
Connector .............................................................. 4 pin
Working range, pressure: ....................................... 40 -400 kPa (6-58.0 psi)
Pressure signal ...................................................... 0.3 -4.8 VDC
Type ...................................................................... Linear
Max. tightening torque ............................................ 3.3 Nm (2.4 lbf-ft)
* The resistance falls as the temperature rises.
11
Oil pressure sensor

Voltage .................................................................. 5 V ± 0.25 VDC
Connector .............................................................. 3 pin
Working range, pressure: ....................................... 0 -1000 kPa (0-145.0 psi)
Pressure signal ...................................................... 0.5 -4.5 VDC
Type ...................................................................... Linear
Fuel temperature sensor

Connector .............................................................. 2 pin
Rated voltage ......................................................... 5 ± 0.15 VDC
Characteristic ........................................................ -40 °C (-40.0°F) 45313 Ω
0 °C (32.0°F) 5896 Ω
23 °C (73.4°F) 2057 Ω
60 °C (140.0°F) 596 Ω
100 °C (212.0°F) 186 Ω
140 °C (284.0°F) 71 Ω
Type ...................................................................... NTC* (Negative Temperature Coefficient)

Max. tightening torque ............................................ 20 -24 Nm (14.7-17.7 lbf-ft)
Air pre-heating (option)

Power .................................................................... 3600 W (24 V), 2000 W (12 V)
* The resistance falls as the temperature rises.
12
Group 23 EDC 4 Design and function
Design and function

System description, EDC 4
EDC 4 (Electronic Diesel Control) and is an electronic system with CAN control (Controller Area Network) for die-
sel engines. The system includes fuel management and diagnostic functions.
All engines can be controlled via CAN, with a potentiometer, or both. The accelerator control required can be set
by using the VODIA tool (including Penta EDC4 software), please refer to the Parameter Setting chapter.
Summary Diagnostic function

The system includes sensors, control unit and an en- The task of the diagnostic function is to discover and
gine speed regulator. The sensors send input signals localize any malfunctions in the EDC 4 system, to
to the control unit, which controls the control rod for protect the engine and to ensure operation in the event
the injection pumps in its turn, by means of an actua- of serious malfunctions.
tor in the engine speed regulator. If a malfunction is discovered, this is notified by the
Input signals diagnostic function, by warning lamps or via the CAN
network. By pressing the diagnostic switch, the opera-
The control unit receives input signals about engine
tor will receive a fault code as a guide for any fault-
operating conditions from the following components:
tracing. Fault codes can also be output via the CAN
– speed sensor, camshaft interface or with Volvo’s VODIA tool (including the
– coolant temperature sensor Penta EDC4 software) at an authorized Volvo Penta
workshop.
– charge pressure sensor
If there is a serious malfunction, the engine is shut
– oil pressure sensor down altogether. Yet again, fault codes can be output
– fuel temperature sensor via diagnostic connector, the CAN interface or with
Volvo’s VODIA tool (including the Penta EDC4 soft-
– coolant level sensor (the function is implemented ware) at an authorized Volvo Penta workshop.
in the control unit as standard, but no sensor is
supplied with the engine)
Output signals
The control unit controls the following components on
the basis of the input signals received:
– engine speed regulator (with position sensor for
the control rod and acutator)
– electric air pre-heating (option)
Information from the sensors provides exact informa-
tion about current operation conditions and allows the
processor to calculate the correct fuel volume, check
engine status etc.
13
Other functions
The EDC4 system contains a number of functions
whose functions include engine protection.
Droop Smoke limiting

Droop is the difference in engine speed between a fully The control unit has an electronic smoke limiting
loaded and unloaded engine. function. This function monitors the charge air
It is possible to switch between two different droop pressure and adjusts the fuel volume to avoid
values while the engine is running. smoke problems during acceleration (only applies
to VE engines).
The droop value can be changed between 0%
(isochronous mode) and 5% (default).
If the droop connector is not connected, the engine Compensation, fuel temperature
runs in isochronous mode (0% droop). The control unit regulates the fuel volume to give
The VODIA tool can be used to change the droop val- the engines the same output power, irrespective of
ue so that the value can be switched between 0% and fuel temperature.
a value between 0 – 10%
“Limp home”
Stability If there is any fault in the signal from the accelera-
The engine speed regulator can be adjusted by means tor pedal, the engine speed is set to 1200 rpm (so-
of the VODIA tool, to trim the engine for a number of called limp home speed).
different applications. Please refer to the “Fine adjust- NOTE! Only applies to VE engines.
ment, engine speed regulator” chapter.
Idling
Fine adjustment, engine speed Idling speed can be adjusted on VE engines, using
Engine speed can be adjusted 8% up and down on the VODIA tool. Default value is 700 rpm.
single 1500 rpm or single 1800 rpm GE engines.
• Single 1500 rpm GE: 1380 rpm - 1620 rpm Altitude correction
• Single 1800 rpm GE: 1656 rpm - 1944 rpm An option for engines which operate at altitudes
This facility is not found on “dual speed” GE engines. above 1,000 m (3,000 foot) above sea level, is an
atmospheric pressure sensor and altitude correc-
tion function. This function limits the fuel volume in
relation to ambient air pressure. This is to prevent
smoke, high exhaust temperature and to protect
the turbocharger from overspeeding. gastempera-
turer och för att skydda turboaggregatet mot över-
varvning.
14
Cold starting
The control unit controls engine speed increase during a
cold start. The control unit limits the number of rpm that
engine speed can increase per second.
Example: For VE engines at -30°C (-22.0°F) , engine
speed can not increase by more than 100 rpm per sec-
ond (units: r/min/s), please refer to the diagram below.
VE engines:
When coolant temperature is between -30 °C (-22.0°F)
and +10 °C (50.0°F) , the control unit increases engine
speed as in the diagram below.
GE engines:
When coolant temperature is between -30 °C (-22.0°F)
and 0 °C (32.0°F) , the control unit increases engine
speed as in the diagram below.
15
Component description
The numbers after the headings refer to the “Compo-
nent location” chapter.
Control unit (EDC 4)

The control unit, which is externally located (not on
the engine), monitors and controls the actuator to give
the correct fuel volume. Regulation is mainly done
with the aid of the engine speed sensor, coolant tem-
perature sensor and the control rod sensor located in
the actuator.
The EDC 4 system processor is encased in the con-
trol module and is protected against moisture and vi-
bration.
The processor receives continuous information about:
• engine speed
• charge air pressure
• coolant temperature
• fuel temperature
• oil pressure
• coolant level (option)
The information provides exact information about cur-
rent operation conditions and allows the processor to
calculate the correct fuel volume, check engine sta-
tus etc.
Speed sensor, camshaft (1)

The engine speed sensor is located on the flywheel
housing, on the right hand side of the engine.
The engine speed sensor for the camshaft is an induc-
tive sensor. The sensor reads camshaft movement
and sends information about engine speed to the con-
trol unit.
Coolant temperature sensor, (3)

The sensor is located at the rear of the cylinder head,
above the actuator.
The sensor senses the engine coolant temperature
and sends the information to the control unit. The sen-
sor consists of a non-linear resistor, whose resistance
is dependent on the temperature of the resistor body.
The resistance falls as the temperature rises.
16
4-pin charge pressure sensor

Charge pressure sensor (4 and 5)
There are two different types of charge pressure sen-
sor. 3-pin charge pressure sensor
The engines are delivered with either a 4-pin or a 3-pin

charge pressure sensor.
The 4-pin charge pressure sensor is located on the in-
let manifold above the engine.
The 3-pin charge pressure sensor is located between
the actuator and the round connector for the control
unit on the right side of the engine.
The charge air pressure sensor measures absolute
pressure, which is the sum of charge pressure plus
atmospheric pressure. The sensor provides a signal
whose resistance is proportional to the absolute air
pressure. The sensor receives a 5 Volt reference volt-
age from the control unit.
Oil pressure sensor (7)

Oil pressure is measured by a sensor located above
the oil filter on the right side of the engine.
The sensor consists of a non-linear resistor, whose re-
sistance is dependent on the temperature of the resis-
tor body. The resistance falls with rising temperature.
The pressure signal is a voltage which is proportional
to the pressure. The reference voltage for the sensor
is 5 Volt.
17
Fuel temperature sensor (6)

The sensor is located on the right hand side of the en-
gine, beside the fuel return pipe union. The sensor is
of the same type as the coolant temperature sensor.
Speed regulator / Actuator (2)

The actuator is located above the flywheel, on the
right hand side of the engine.
The actuator consists of a control solenoid which oper-
ates the control rod for the injection pumps, and a con-
trol rod sensor which measures the position of the
control rod.
A signal from the accelerator goes to the control unit,
which sends a signal to the control solenoid, which op-
erates the control rod in its turn. Information about the
true position of the control rod is sent back to the con-
trol unit via the control rod position sensor, which can
then fine-tune the amount of fuel injected.
If the current to the actuator is cut, the control rod is
forced back by the return spring. Fuel injection then
ceases and the engine stops.
18
Alternator
The alternator is belt driven and is located at the front
of the engine.
The voltage regulator on the alternator is provided
with a sensor system. The sensor system compares
the charge voltage across the alternator terminals, B+
and B-, with the current voltage across the positive
and negative battery terminals. The voltage regulator
then compensates for any voltage drop in the cables
between the alternator and the battery, by increasing
the charge voltage supplied by the alternator as nec-
essary.
Starter motor
The starter motor is installed on the flywheel housing,
on the left-hand side of the engine.
When engaged, a gear wheel is first slid axially along
the starter motor rotor spindle, so that it engages on
the gear ring on the engine flywheel. The axial move-
ment of the gear, and connection of the starter motor,
are controlled by an actuator solenoid on the starter
motor.
The starter motor solenoid is engaged via the starter
relay in its turn, which is activated when the starter
key is turned to position III or the start button is de-
pressed.
Electric heat pre-heating

A module for air pre-heating is available as an option.
The EDC4 control module controls air pre-heating via
this module.
19
Component location
1. Speed sensor, camshaft

2. Speed regulator / Actuator
3. Coolant temperature sensor
4. Charge pressure sensor, 3 pin*
5. Charge pressure sensor, 4 pin*
6. Connection to control unit
7. Fuel temperature sensor
8. Oil pressure sensor
* Only one type of sensor is used.
20
Group 23 EDC 4 Limit values
Limit values
These functions are customer parameters and can be shut off completely.
NOTE! The diagnostic lamp flashes when the alarm limit is reached, even if the function is shut off.
Alarm limits:
Coolant temperature: Warning lamp, coolant temp. lights up Engine is stopped
Default value Volvo Penta 110 °C (230.0°F) 113 °C (235.4°F)
(goes out at 109°C (228.1°F)) after 30 sec.
Coolant level:
The control unit does not check this function until 25 s after starting. When the control unit receives a low coolant
level signal, the engine is shut off after 5 sec.
Oil pressure:
The control unit does not check this function until 30 s after starting.
The limit values depend on engine speed. The diagnostic lamp lights up when the limit value is reached, and goes
out again when the oil pressure has risen 10% above the limit value. The engine is shut off when oil pressure falls
to 80% of the limit value.
Warning lamp, oil pressure, lights up Engine is stopped

Examples of default values: 800 rpm: 0.9 bar (13.0 psi) 0.72 bar (10.4 psi)
(goes out at 1 bar (14.5 psi))
2000 rpm: 2.5 bar (36.2 psi) 2 bar (29.0 psi)
(goes out at 2.75 bar (39.8 psi))
21
Group 23 EDC 4 Parameter setting
Parameter setting
Adjustable parameters
The VODIA tool can be used to read and adjust the
parameters below, in “Parameter Programming” mode:
Please refer to the “VODIA User’s Guide” for advice
on use.
NOTE! Special authorization is needed to be able to
adjust certain parameters.
Idling speed voltage error
Full throttle voltage A fault code is set if the signal falls below the mini-
mum value.
Voltage at the throttle control input which corresponds
to full throttle. Min. value 0V
Min. value 0V Default value 0.1 V
Default value 4.6 V Max. value 5V
Max. value 5V
Idling speed.
Maximum speed voltage error Setting idling speed
A fault code is set if the maximum value is exceeded. Min. value 0 r/min
Min. value 0V Default value 700 r/min
Default value 4.9 V Max. value 4000 r/min
Max. value 5V
Idle voltage
Voltage at the throttle control input which corresponds
to idling.
Min. value 0V
Default value 0.3 V
Max. value 5V
22
PID regulator P section Coolant temperature protection

(Special authorization needed)
P section which is used to control engine speed
Chooses whether engine protection should be activated
Min. value 0%
in relation to high coolant temperature.
Default value VE: 10 %, GE: 30 % Alternative positions “Off” or “On”
Max. value 100 % Default value: “On”
If “On”, the coolant temperature warning lamp lights up
PID regulator I section at 110 °C (230.0°F) (goes out at 109°C (228.1°F))
The engine is shut off at 113 °C (235.4°F) after 30 sec.
I section which is used to control engine speed
Min. value 0%
Coolant level protection
Default value VE: 50 %, GE: 85 % (special authorization needed)
Max. value 100 % Chooses whether engine protection should be activated
in relation to low coolant level.
Alternative positions “Off” or “On”
PID regulator D section
Default value: “On”
D section which is used to control engine speed
If “On”, the control unit does not check this function
Min. value 0% until 25 s after starting. When the control unit receives
Default value VE: 4 %, GE: 3 % a low coolant level signal, the engine is shut off after 5
sec.
Max. value 100 %
Oil level protection

Droop (special authorization needed)
Selects the amount of droop to be used. Chooses whether engine protection should be activated
in relation to low oil pressure.
Min. value 0%
Alternative positions “Off” or “On”
Default value 5%
Default value: “On”
Max. value 100 %
If “On”, the control unit does not check this function
until 30 s after starting.
Accelerator control type (special authorization The limit values depend on engine speed. The oil pres-
needed) sure warning lamp lights up when the limit value is
Selects the type of accelerator control to be used. reached, and goes out again when the oil pressure has
risen 10% above the limit value. The engine is shut off
Alternative modes:
when oil pressure falls to 80% of the limit value.
– None
Examples of default values:
– Potentiometer
800 rpm - the oil pressure warning lamp lights up at 0.9
– CAN bar (13.0 psi) (goes out at 1 bar (14.5 psi) ) and the en-
– Both gine is shut off at 0.72 bar (10.4 psi) .
2000 rpm - the oil pressure warning lamp lights up at
2.5 bar (36.2 psi) (goes out at 2.75 bar (39.8 psi) ) and
CAN communication (special authorization needed)
the engine is shut off at 2 bar (29.0 psi) .
CAN communication on or off.
Alternative modes “Off” or “On” Control rod
Default value: VE engines: “On” (Special authorization needed)
Control rod calibration.
GE engines “Off”
Min. value 0 mm (0”)
Max. value 20 mm (0.7874")
23
Read-only parameters Fine adjustment, engine speed

The VODIA tool can be used to read and the values regulator
below, in “Log test” mode: Please refer to the “VODIA Each control unit supplied with the engine or as a
User’s Guide” for advice on use. spare part has a default setting. The default setting is
• Battery voltage chosen to allow the engine to work in most applica-
tions.
• Coolant temperature
In certain circumstances, the engine can run unevenly
• Charge air pressure or behave in an undesirable manner. If this is the
• Oil pressure case, the engine should be checked in the order and
using the procedures below:
• Fuel temperature
1. Check whether the control unit has set a fault
• Engine speed code and rectify this if necessary, in accordance
Accelerator linkage % with the “Diagnostic functions” and “Fault codes”
•
chapters.
• Droop %
2. Check and attend to possible symptoms in ac-
• Accelerator position voltage (Only in “Parameter cordance with the “Fault tracing” chapter.
Programming” mode in the VODIA tool).
3. Check and adjust the engine speed regulator as
• Engine total running time below.
• Engine loading %
Use the VODIA tool (including Penta EDC4 software),

to read and adjust the P, I and D sections of the en-
gine speed regulator. In some cases, this can offer
more stable and more even engine running.
PID = Proportional, Integrating, Differential
The P section amplifies (Gain). A reduced value
(Fig. 1) gives slower regulator reaction to load chang-
es. An increased value (Fig. 2) gives faster reaction.
The I section stabilizes (Stability). A reduced value
(Fig. 3)
increases the time taken by the system to recover af-
ter a load change. An increased value (Fig 4) gives a
shorter recovery time.
The D section stabilizes (Differential). Reacts to the
magnitude of the engine speed change. A reduced
value (Fig 4) gives reduced sensitivity. An increased
value (Fig. 5) gives increased stability.
Before any adjustments are made, the current values
of the P, I and D sections of the PID regulator should
be noted.
NOTE! Without the default values, the engine speed
regulator / actuator can not be restored if adjustment
is not successful.
Please refer to the “VODIA User’s Guide” for advice
on use.
24
Adjustment
1. Use the VODIA tool and note the current values of
rpm
the P, I and D sections of the PID regulator.
Demanded engine speed
2. Start the engine.
3. Run the engine at working speed without load, and
first increase the value of the P section of the PID
regulator until unstable (oscillating) engine speed
True engine speed
is achieved. Then reduce the parameter by 1-2%
until the engine speed is stable again.
4. Then adjust the I section of the PID regulator in time
the same way as above. Fig 3. I section too low
5. If the engine still runs badly and no other adjust-

ments help, increase the D section of the PID
regulator until the engine only has a very small in-
crease in speed when load is applied or removed,
please refer to fig. 6.
rpm
NOTE! The few times that the D section may Demanded engine speed
need to be adjusted include cases where the ap-
plication has a flexible coupling or extremely low
flywheel inertia.
6. Adjust the P and I sections again as above, if True enginevarvtal
Verkligt speed
necessary.
7. Check engine response as fig. 6. time
Fig 4. I section too high or D section too low
rpm

rpm
True engine speed
True engine speed time

Fig 5. D section too high
time
Fig 1. P section too low
rpm Load removal

rpm
True engine speed

Load application
time
time Fig 6. Demanded response
Fig 2. P section too high
25
Repair instructions
Working on the EDC4 system
Follow the instructions below, to avoid damage to the EDC4 system control unit.
• Never turn off the main switch when the engine is running.
• Never undo the battery cables when the engine is running.
• When the batteries are quick charged, turn the main switch off or undo the battery cables.
During normal maintenance charging, the main switch does not need to be turned off.
• Only batteries may be used for start help. Quick starting units can give excess voltages and damage the con-
trol module.
• Disconnect the EDC4 system from system voltage before undoing either of the 25 pin connectors on the con-
trol unit.
• If you discover any damage on the cable harnesses, undo the connector on the control unit.
IMPORTANT! Always undo the connectors on the control unit before doing any welding.
• When a connector is undone from a sensor, be careful to ensure that the connector pins are not exposed to
oil or other fluids. The consequence of this can be contact problems, or if oil runs down onto the pressure
sensing diaphragm, the sensor will indicate an incorrect value.
26
Control unit, change

Each control unit is tied to a specific engine via the
engine serial number. This means that it is not possi-
ble to transfer a control unit from one engine to anoth-
er.
If a control unit is changed, the new control unit must
have that particular engine’s:
– data setup (firmware)
– engine number.
1. Disconnect system voltage from the engine.

2. Disconnect the cable connectors from the control
unit.
3. Install the new control unit.
4. Connect the cable connectors to the control unit.
NOTE! The control unit must not be installed on the

engine.
Speed regulator, change

To change the engine speed regulator, please refer to
the workshop manuals for each mechanical engine
(not EDC).
Please refer to the workshop manual, “Industrial en-
gines, TD520GE, TAD520GE, TD520VE, TAD520VE,
TD720GE, TAD720GE, TD720VE, TAD720VE,
TAD721GE, TAD721VE, TAD722GE, TAD722VE”
or
workshop manual, “Industrial engines TD420VE,
TAD420VE, TAD620VE”.
27
Starting with auxiliary

batteries
WARNING! Ventilate well. Batteries generate an
explosive gas which is highly flammable and ex-
plosive. A short circuit, open flame or spark
could cause an explosion.
WARNING! Never switch over the battery cable

positions on the battery. Switching the battery
terminals over when using jumper cables for
start help causes short circuits and arcing,
which could cause an explosion and cause con-
siderable damage to electrical components on
the engine.
1. Check that the voltage of the help start battery is

the same as the system voltage of the engine.
2. First connect the red (+) jumper cable to the posi-
tive (+) pole on the flat battery, then to the posi-
tive (+) pole on the auxiliary battery.
3. Then connect the black jumper cable to the nega-
tive pole (–) of the help start battery, and to a
place some distance from the flat battery, such
as the negative connection on the starter motor.
WARNING! Under no circumstances may the

black jumper cable (–) come into contact with
the positive cable connection on the starter mo-
tor.
4. Start the engine and run at a fast idle for about 10

minutes to charge the batteries.
WARNING! Working with, or going close to a

running engine is a safety risk.
Watch out for rotating components and hot sur-
faces. Do not touch the connections during the
start attempt. Risk of arcing. Do not stand bent
over any of the batteries either.
5. Switch off the engine.

Remove the jumper cables in the exact reverse
order from installation. One cable at a time!
28
Group 23 EDC 4 Function check
Function check
Diagnostic function for VODIA (including Penta EDC 4 software)

• The program can read fault codes which have been stored in the engine control unit, check input and output
signals, read off current values from engine sensors, and then store and print out test results.
• The program allows service and workshop personnel to quickly localize and attend to faults in the EDC4 sys-
tem.
• It is connected to the engine control unit via a diagnostic connector (VODIA input), please refer to the “Wiring
schedule” chapter.
• User information is included with the program.
• Please contact your Volvo Penta dealer to order the software.
• The task of the diagnostic function is to discover and localize any malfunctions in the EDC 4 system, to pro-
tect the engine and to ensure operation in the event of serious malfunctions.
• If a malfunction is found, the diagnostic indicator in the control panel begins to flash. A diagnostic trouble
code (DTC) can be obtained by pressing the diagnostic button, as a guide for any fault-tracing.
Please refer to the “VODIA User’s Guide” for more information and advice on use.
29
Group 23 EDC 4 Function check
Fault tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below. Always con-
tact your Volvo Penta dealer if any problems occur which you can not solve by yourself.
WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chap-
ter before starting work.
Symptoms and possible causes

The diagnosis button lamp flashes. Please refer to the
“Diagnostic information” chapter.
Engine can not be stopped. 2, 4
Starter motor does not rotate 1, 2, 3, 4, 5, 6, 7, 24
Starter motor rotates slowly 1, 2
Starter motor rotates normally but engine does not start 8, 9, 10, 11
Engine starts but stops again 8, 9, 10, 11, 13
Engine does not reach correct operating speed at full throttle 9, 10, 11, 12, 13, 21, 25, 26
Engine runs roughly 10, 11, 27
High fuel consumption 12, 13, 15, 25
Black exhaust smoke 12, 13
Blue or white exhaust smoke 14, 15, 22
Too low lubrication oil pressure 16
Excessive coolant temperature 17, 18, 19, 20
Too low coolant temperature 20
No, or poor charge 2, 23
1. Flat batteries 11. Water/contamination in fuel 21. Blocked intercooler

2. Poor contact/open circuit in 12. Faulty injection pumps 22. Too high oil level
cables
13. Insufficient air supply to engine: 23. Alternator drive belt slips
3. Main switch turned off - blocked air filter
24. Water entry into engine
- air leakage between turbo
4. Faulty ignition lock
charger and engine inlet pipe. 25. High back pressure in
5. Faulty main relay - fouled compressor section in exhaust system
6. Faulty starter motor relay turbocharger 26. Break in “Pot+” cable to
- faulty turbocharger pedal
7. Faulty starter motor/solenoid - poor engine bay ventilation
27. Incorrectly set engine
8. Lack of fuel: 14. Excessive coolant temperature
speed regulator / actuator
- fuel taps closed
15. Too low coolant temperature (PID regulator)
- fuel tank empty/wrong tank
connected 16. Too low oil level
9. Blocked fuel filter/pre-filter 17. Coolant level too low
(because of contamination, or
18. Air in the coolant system
paraffin fraction separation in
fuel at low temperature). 19. Faulty circulation pump
10. Air in the fuel system 20. Defective thermostat
30
Group 23 EDC 4 Diagnostic function
Diagnostic function
The diagnostic function monitors and checks that the
EDC 4 system functions normally.
Diagnostic function, tasks Effect on engine

The diagnostic function has the following tasks: The diagnostic function affects the engine in the fol-
• Discover and localize malfunctions. lowing ways:
1. The diagnostic function has discovered a minor
• Notify that malfunctions have been discovered.
malfunction which does not damage the engine.
• Give advice in fault finding.
Reaction: The engine is not affected. The diag-
• Protect the engine and ensure continued operation nostic lamp lights up.
when serious malfunctions are discovered.
2. The diagnostic function has discovered a serious
malfunction which makes it impossible to control
Malfunction message the engine.
If the diagnostic function discovers a malfunction in Reaction: The diagnostic lamp starts to flash. En-
the EDC 4 system, this is notified via the CAN bus or gine is shut off.
the diagnostic lamp lights up or starts to flash. At the
same time, the fault is stored in the control unit mem-
ory. As soon as the fault has been attended to and the
Operation
ignition is turned off and on, the fault code lamp goes
out. Both rectified (passive) and un-rectified (active) During starting
faults are stored in the control unit and can be read by When the ignition is turned on, the diagnostic lamp
an authorized workshop. lights up for two seconds, together with the warning
lamps for oil pressure and coolant. This is to check
the lamp function.
Fault tracing guide
If the diagnostic lamp flashes after the two seconds,
If the diagnostic switch is depressed (for 1-3 seconds) this indicates a serious fault and the engine can not
and then released, a fault code is flashed out from the be started. One or more fault codes can then be
diagnostic lamp. The fault code is found in the fault flashed out.
code list, with information about the reason, reaction
and measures to be taken. Please refer to the “Fault If the diagnostic lamp is lit, there are one or more less
codes” chapter. serious faults. One or more fault codes can then be
flashed out.
31
Group 23 EDC 4 Diagnostic function
During operation The fault code consists of three groups of flashes,

separated by a pause of two seconds.
The first and third group consist of short flashes (0.4
If the diagnostic lamp starts to flash during operation:
s). The second group consists of long flashes (0.8 s).
1. Reduce engine speed to idling.
A fault code is obtained by counting the number of
2. Press the diagnostic button (for 1-3 seconds). flashes in each group.
3. Release the diagnostic button and make a note of Example: (2 short) pause (2 long) pause
the diagnostic trouble code (DTC) that is flashed (1 short) = Fault code 2.2.1
out. Please refer to “Reading fault codes” below. The fault code is stored and can be read as long as
4. Look up the fault code in the fault code list and the fault remains. You can find information about
take the necessary measures. Please refer to the cause, reaction and actions in the fault code list.
“Fault codes” chapter. Please refer to the “Fault codes” chapter.
If the diagnostic lamp starts to flash, the engine will Read as follows:
be emergency stopped. 1. Press the diagnostic button (for 1-3 seconds).
IMPORTANT! In VE engines, there is a function 2. Release the diagnostic button and make a note of
in the system which makes it possible to start the fault that is flashed out.
the engine again and run it for about 25 sec- 3. Repeat items 1-2. A new fault code is flashed out
onds. This is so that the vehicle can be moved if more are stored. Repeat until the first fault code
from a railway level crossing etc. is repeated.
NOTE! When the first fault code is repeated, all fault
Reading fault codes codes have been read out.
Fault codes can either be read via: When all faults have been rectified:
– The VODIA tool (including the Penta EDC4 soft- 1. Turn the ignition on and off.
ware). Please refer to the “VODIA User’s Guide” 2. Press the diagnostic button (for 1-3 seconds) to
for advice on use. check whether any faults remain.
– Diagnostic lamp 3. If there are no active faults, the diagnostic lamp
– CAN will give two short flashes, in other cases the re-
maining non-rectified faults will be flashed out
again.
Diagnostic lamp
If the diagnostic lamp is illuminated or flashes, a fault
code can be read by pressing the diagnostic button
(for 1-3 seconds) and then releasing it. The diagnostic
lamp goes out, and a fault code is then flashed out.
32
Group 23 EDC 4 Fault codes
Fault codes
WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chap-
ter before starting work.
Code 2.0.0 No faults PID 190, Code 2.1.4 Overspeed

There are no active faults. Reason: The engine speed is or has been higher than the
permissible limit.
Reaction: Fuel injection ceases and the fault code lamp
PID 190, Code 2.1.1 Engine speed sensor, lights up until the engine speed falls below the permissible
camshaft limit again.
Reason: Faulty sensor, connector, cables or incorrect dis- Action:

tance to cam wheel. High frequency interference. Check the control rod for the injection pumps,
•
Reaction: Engine is shut off. please refer to workshop manual “Industrial en-
gines TD520GE, TAD520GE, TD520VE,
Action:
TAD520VE, TD720GE, TAD720GE, TD720VE,
• Check that the engine speed sensor is installed TAD720VE, TAD721GE, TAD721VE, TAD722GE,
with the correct distance to the camshaft. TAD722VE” or to workshop manual “Industrial en-
Check the cables for the engine speed sensor for gines TD420VE, TAD420VE, TAD620VE”.
•
breaks and short circuits. • Check the actuator, replace it if necessary, please
Check the connector for poor contact. refer to chapter
• “Fault tracing of engine speed regulator” or “Engine
• Check engine speed sensor function. Change the speed regulator, change”.
sensor as necessary.
• Check the cables for the actuator for breaks and
short circuits.
• Check the number of teeth on the camshaft wheel.
• For VE engines, it may be necessary to check the

function of the “limp home” mode
PID 91, Code 2.2.1 Accelerator pedal sensor

Reason: Faulty sensor, connector or cable.
Reaction: The engine goes into “limp home” mode.
Action:
• Check the sensor cable for breaks and short cir-

cuits.
• Check sensor function. Change the sensor as nec-

essary.
33
PID 102, Code 2.2.3 Charge pressure sensor PID 174, Code 2.2.7 Fuel temperature sensor
Reason: Faulty sensor, connector or cable. Reason: Faulty sensor, connector or cable.
Reaction: A fault code is generated. Reaction: A fault code is generated.
Action: Action:
• Check the sensor cable for breaks and short cir- • Check the sensor cable for breaks and short cir-
cuits. cuits.
• Check the sensor function, please refer to the • Check the sensor function, please refer to the
“Electrical fault tracing” chapter. Change the sen- “Electrical fault tracing” chapter. Change the sen-
sor as necessary. sor as necessary.
PID 100, Code 2.2.4 Oil pressure sensor PID 100, Code 2.3.1 Warning, oil pressure
Reason: Faulty sensor, connector or cable. Reason: Oil pressure below specified limit value (de-
pends on engine speed).
Reaction: A fault code is generated.
Reaction: A fault code is generated. The fault code disap-
Action:
pears when the oil pressure exceeds the recuperation val-
Check the sensor cable for breaks and short cir- ue.
•
cuits. Action:
• Check the sensor function, please refer to the Check the oil level and oil pump.
•
“Electrical fault tracing” chapter. Change the sen-
sor as necessary. • Check the sensor cable for breaks and short cir-
cuits.
• Check the sensor function, please refer to the

PID 110, Code 2.2.5 Temperature sensor, coolant “Electrical fault tracing” chapter. Change the sen-
sor as necessary.
Reason: Faulty sensor, connector or cable.
• Check the limit value for oil pressure warning,
Reaction: A fault code is generated.
please refer to the “Limit values” chapter.
Action:

cuits. PID 110, Code 2.3.2 Warning, coolant temperature
• Check the sensor function, please refer to the Reason: Excessive coolant temperature
“Electrical fault tracing” chapter. Change the sen- Reaction: A fault code is generated. The fault code disap-
sor as necessary. pears when the coolant temperature falls below the recu-
peration value.
Action:
• Check the coolant.

cuits.

sor as necessary.
34
PID 111, Code 2.3.5 Warning, coolant level PID 174, Code 2.3.7 Warning, fuel temperature
Reason: Coolant level too low Reason: Excessive fuel temperature.
Reaction: A fault code is generated. Reaction: A fault code is generated. The fault code disap-
pears when the fuel temperature falls below the recupera-
Action:
tion value.
• Check the coolant level. Action:
• Check the sensor cable for breaks and short cir- Check the fuel.
•
cuits.
• Check sensor function (if installed). cuits.
Change the sensor as necessary.
NOTE! The engine is supplied without a coolant level sen- “Electrical fault tracing” chapter. Change the sen-
sor. sor as necessary.
PID 190, Code 2.3.6 Overspeed in limp home PID 100, Code 2.3.1 Emergency stop, oil pressure
mode
Reason: Oil pressure below specified limit value.
Reason: When the limp home mode is activated and the
Reaction: Engine is emergency stopped.
engine speed is or has been higher than the permissible
limit value. Action:
Reaction: GE: Engine is shut off. A fault code is generat- Check the oil level and oil pump.
•
ed.
VE: Fuel injection ceases when the control rod returns to cuits.
its home position and the fault code lamp lights up until
the engine speed falls below the permissible limit again. • Check the sensor function, please refer to the
Action: “Electrical fault tracing” chapter. Change the sen-
sor as necessary.
• Check the control rod for the injection pumps,
please refer to workshop manual “Industrial en- • Check the limit value for engine shut-off due to oil
gines TD520GE, TAD520GE, TD520VE, pressure.
TAD520VE, TD720GE, TAD720GE, TD720VE,
TAD722VE” or to workshop manual “Industrial en- PID 110, Code 2.3.2 Emergency stop, coolant
gines TD420VE, TAD420VE, TAD620VE”. temperature
• Check the actuator, replace it if necessary, please Reason: Excessive coolant temperature
refer to chapter Reaction: Engine is emergency stopped.
“Fault tracing of engine speed regulator” or “En- Action:
gine speed regulator, change”.
• Check the coolant.
• Check the cables for the actuator for breaks and
short circuits. • Check the sensor cable for breaks and short cir-
cuits.
• Check the number of teeth on the camshaft
wheel. • Check the sensor function, please refer to the
• For VE engines, it may be necessary to check the sor as necessary.
function of the “limp home” mode
• Check the limit value for engine shut-off due to
coolant pressure.
35
PID 111, Code 2.3.5 Emergency stop, coolant SID 23, Code 2.5.1 Control rod position sensor,
level difference
Reason: Low coolant level
Reaction: The engine is emergency stopped and can not Reason: Injection pump/actuator has got stuck or is not
be re-started until the fault is rectified. connected. Difference between control rod current value
and nominal value exceeds 10%.
Action:
• Check coolant level. pears when the difference between control rod current
Check the sensor cable for breaks and short cir- value and nominal value falls below 10%.
•
cuits. Action:
• Check sensor function (if installed). • Check the control rod for the injection pumps,
Change the sensor as necessary. please refer to workshop manual “Industrial en-
NOTE! The engine is supplied without a coolant level sen- gines TD520GE, TAD520GE, TD520VE,
sor. TAD520VE, TD720GE, TAD720GE, TD720VE,
TAD722VE” or to workshop manual “Industrial en-
gines TD420VE, TAD420VE, TAD620VE”.
SID 24, Code 2.5.1 Control rod position sensor
Reason: Actuator not connected. Faulty value from control • Check the actuator, replace it if necessary, please
rod position sensor in actuator. refer to chapter “Fault tracing of engine speed
regulator” or “Engine speed regulator, change”.
Reaction: Engine is emergency stopped. Actuator can not
be controlled. • Check the cables for the actuator for breaks and
short circuits.
Action:
• Check the actuator, replace it if necessary, please

refer to chapter “Fault tracing of engine speed
SID 23, Code 2.5.2 Injection pump, auto
calibration
• Check the cables for the actuator for breaks and Reason: Automatic actuator equalization is not possible.
short circuits. Faulty calibration.
Reaction: The engine is emergency stopped and can not
be re-started until the fault is rectified. The regulator can
SID 24, Code 2.5.1 Control rod position sensor, not be activated.
reference
Action:
Reason: Actuator not connected. Faulty value from control
rod position sensor in actuator. • Check the actuator, replace it if necessary, please
Reaction: Engine is emergency stopped. Actuator can not regulator” or “Engine speed regulator, change”.
be controlled.
• Check the actuator cables.
Action:
• Turn the ignition off and on, and check if the fault
• Check the actuator, replace it if necessary, please
code remains.
• Check the cables for the actuator for breaks and SID 231, Code 2.7.1 Communication fault, CAN
short circuits. bus
Reason: CAN controller for CAN bus is faulty.
Reaction: --
Action:
• Check the cables.
• Check the control unit.
36
SID 252, Code 2.8.1 Parameter programming PID 158, Code 2.8.2 Reference voltage 2
Reason: Memory fault Reason: Reference voltage for actuator exceeds permis-
sible limit values.
be re-started until the fault is rectified. Reaction: A fault code is generated. The fault code disap-
pears when the voltage returns to within the permissible
Action:
limit values (5 V).
• Turn the ignition off and on, and check if the fault Action:
code remains.
• Check the voltage supplied.
SID 240, Code 2.8.1 Cyclical program test code remains.
Reason: Memory fault
be re-started until the fault is rectified.
PID 158, Code 2.8.2 Reference voltage 3
Action: Reason: Reference voltage for actuator exceeds permis-

sible limit values.
code remains. pears when the voltage returns to within the permissible
limit values (5 V).
Action:
PID 158, Code 2.9.1 Control unit, voltage supply
Reason: Voltage supplied to actuator exceeds permissi-
ble limit values. • Turn the ignition off and on, and check if the fault
code remains.
limit values.
Action:
code remains.
PID 158, Code 2.8.2 Reference voltage 1

Reason: Reference voltage for actuator exceeds permis-
sible limit values.
limit values (5 V).
Action:
code remains.
37
PID 48, Code 2.9.2 Atmospheric pressure

Reason: Air pressure is outside permissible values.
pears when the pressure returns to normal. Monitoring
function for air pressure is de-activated.
Action:
code remains.
SID 253, Code 2.10.1 Parameter fault

Reason: No data or incorrect data (fault only occurs dur-
ing parameter setting or reset).
Reaction: Engine can not be started.
Action:
• Check parameter settings.
code remains.
SID 240, Code 2.10.1 Stack overflow

Reason: Internal calculation fault.
be re-started until the fault is rectified.
Action:
code remains.
38
Group 23 EDC 4 Electrical fault finding
Electrical fault finding
General Function checking of cables

The following should be checked before electrical and connectors
fault tracing starts: First check that none of the circuit breakers has
• Fault codes tripped.
• Fuel level and filter Use multimeter 9510060 to measure the cables.
• Coolant level Connect adapter 885675 between the engine cable

connector and the control unit.
• Air filter
Check the wiring schedule to ensure that measure-
• Battery
ment is done at the correct place.
• Cables (visual)
Use multimeter 9510060 to measure the cables.
• Main switch, circuit breakers, connectors
NOTE! Never do measurements by poking a probe
• Relay connections through insulation.
Check all measurements against the data read from
Electric fault finding can be done on the following the wiring schedule.
components: If a measurement value can not be interpreted from
• Actuator the wiring diagram, check the wires separately.
• Engine speed sensor Contact problems

• Coolant temperature sensor Intermittent contact or temporary recurring faults can
be difficult to fault trace, and are frequently caused by
• Charge air/charge air sensor.
oxidation, vibration or poorly terminated cables.
• Oil pressure sensor
Wear can also cause faults. For this reason, avoid
• Fuel temperature sensor
disconnecting a connector unless it is necessary.
• Starter motor
Other contact problems can be caused by damage to
• Alternator pins, sockets and connectors etc.
Shake cables and pull connectors during measure-
ment, to find where the cable is damaged.
Resistance in connectors, cables and junctions
should be 0 Ohm.
A certain amount of resistance will occur, however,
because of oxidation in connectors.
If this resistance is too great, malfunctions occur. The
amount of resistance that can be tolerated before mal-
functions occur varies, depending on the load in the
circuit.
39
Check the following: Open circuit

• Look for oxidation which can impair contact in con-
nectors.
Chafed or torn cables and connectors which have
come loose can be possible fault causes.
• Check that terminals are undamaged, that they are

correctly inserted into their connectors, and that
Use the wiring schedule to check the cable harnesses
which are relevant to the function. Start off with the
the cable is correctly terminated in the terminal. most probable cable harness in the circuit.
• Test whether the sockets give good mechanical

contact. Use a loose pin for this test.
Check the following:
• Disconnect the relevant connector at each end of
the cable harness.
Important! The engine management unit con-
nector must only be checked by means of gauge • Use multimeter 9510060-8 to measure the resist-
9998482. ance between the ends of the cable. Nominal val-
ue R ~ 0 Ω.
• Carefully insert gauge 9998482 into the connec-
• Shake cables if possible, and pull connectors dur-
tors. Pull the gauge back and forwards a few
ing measurement, to find where the cable is dam-
times, and feel whether the connectors grip the
aged.
gauge. If the connectors have lost their grip, or if
they are weak, change the spade terminals. • If the fault can not be found, check the next cable
harness as in the wiring schedule.
Please refer to the “Joining electrical cables for
multi-connector” chapter.
• Fill sockets which have been checked with low
temperature grease 1161417-9.
Contact resistance and oxidation
Resistance in connectors, cables and junctions
Important! Pressure sensors must not be filled should be 0 Ω.
with grease. A certain amount of resistance will occur, however,
because of oxidation in connectors.
• Check that the cables are correctly clamped.
Avoid clamping cables in a very tight radius be- If this resistance is too great, malfunctions occur. The
side connectors. amount of resistance that can be tolerated before mal-
functions occur varies, depending on the load in the
circuit.
Check the following:

Fault tracing of cables and
connectors
• Look for oxidation which can impair contact in
connectors.
Do a visual check on connectors • Check that terminals are undamaged, that they
are correctly inserted into their connectors, and
Check the following: that the cable is correctly terminated in the termi-
nal.
• Look for oxidation which can impair contact in
connectors. • Test whether the sockets give good mechanical
• Check that terminals are undamaged, that they
are correctly inserted into their connectors, and
Important! Pressure sensors must not be filled
that the cable is correctly terminated in the termi-
with grease.
nal.
• Test whether the sockets give good mechanical
• Shake cables if possible, and pull connectors dur-
ing measurement, to find where the cable is dam-
aged.
40
Joining electrical cables for

multi-connectors
Special tools: 951 2636, 9999324
Repair kit: 1078054
1. Remove the connectors from the control unit,

please refer to “Control unit, change”. Disassem-
ble the connector, to gain access to the cable
leading to the pin which is to be changed.
2. Remove the pin, using tool no. 9512636 or a very
small jeweler’s screwdriver.
NOTE! Only remove one pin at a time.
3. Cut off the cable and the pin which is to be

changed. Join the cable with the new one, using
repair kit 1078054. Use cable crimping tool no.
9999324.
4. Carefully heat the joint with a hot air gun, to make
the insulation shrink and seal tightly.
5. Put the pin back in the right place in the connec-
tor before removing the next pin, if several pins
are to be changed. Check that the locking tab on
the pin locks the pin into the connector.
6. Install the cables with insulation and tie wraps in
the connectors, in the reverse order to disassem-
bly.
7. Install the connectors in reverse order to disas-
sembly.
8. Make sure that the connector and the connection
on the control unit are clean and dry.
9. Connect the connectors to the control unit, please
refer to “Control unit, change”.
10. Start the engine and check carefully that no fault
codes occur.
41
Inspection/fault tracing of components
Checking the sensor, charge pressure
NOTE! There are two different types of charge pres-

sure sensors. A 3-pin and a 4-pin sensor.
1. Shut the engine off

2. Undo the connector on the charge air pressure
sensor and connect adapter no. 885675 between
the charge air pressure sensor connector and the
engine cable harness. Then connect multimeter
9510060-8 between measurement points 1-3 (ap-
plies to both sensors).
3. Turn the control voltage on.
4. Measure, with the multimeter set to voltage meas-
urement. Check that the multimeter indicates 5.0
Volt.
5. Then connect the multimeter between measure-
ment points:
1–2 (for 3-pin sensor)
1-4 (for 4-pin sensor)
At normal atmospheric pressure, the voltage
should be about:
0.8 V ± 0.05 V (for 3-pin sensor)
1.2 V ± 0.05 V (for 4-pin sensor)
Max. tightening torque:

18 Nm (13.2 lbf-ft) (3-pol)
3.3 Nm (2.4 lbf-ft) (4-pol)
42
Checking the sensors, coolant and fuel

temperature
Temperature Resistance
-20 °C (-4.0°F) 15462 Ω
-10 °C (14.0°F) 9397 Ω
0 °C (32.0°F) 5896 Ω
10 °C (50.0°F) 3792 Ω
20 °C (68.0°F) 2500 Ω
23 °C (73.4°F) 2057 Ω
30 °C (86.0°F) 1707 Ω
40 °C (104.0°F) 1175 Ω
50 °C (122.0°F) 834 Ω
60 °C (140.0°F) 596 Ω
70 °C (158.0°F) 435 Ω
The same type of sensor is used for both coolant tem- 80 °C (176.0°F) 323 Ω
perature and fuel temperature.

2. Undo the connector and remove the sensor from
the engine.
3. Use multimeter no. 9510060-8 to measure across
the two contact pins on the sensor. The multime-
ter should shows the values on the adjacent table
and graph.
NOTE! The sensor is highly sensitive to temperature

changes. When measuring in the lower temperature
ranges of 0–40 °C (32-104.0°F) , it is enough to hold
the sensor in your hand for the value to drop rapidly.
Max. tightening torque: 20 -24 Nm (14.7-17.7 lbf-ft)
43
Checking the speed sensor, camshaft Checking the sensor, oil pressure
In a visual check, first remove the sensor from the en- 1. Shut the engine off
gine. Then undo the connector and check that the sen-
2. Undo the connector on the oil pressure sensor
sor is undamaged, and that no swarf has stuck on the
and connect the 4-pin adapter no. 885675 be-
sensor.
tween the oil pressure sensor connector and the
Do an induction test as follows: engine cable harness. Then connect multimeter
1. Shut the engine off 9510060-8 between measurement points 1-3.
2. Undo the engine speed sensor connector.. 3. Turn the control voltage on.
3. Set multimeter 9510060-8 to resistance measure- 4. Measure, with the multimeter set to voltage meas-
ment. Use the multimeter to measure between the urement. Check that the multimeter indicates
engine speed sensor pins. The multimeter should 5.0 Volt.
show 336 Ω ± 34 Ω 5. Then connect the multimeter between measure-
4. Move a metal object quickly past the sensor, at a ment points 1-2. The voltage should be about
close distance. Check that the multimeter gives a 0.5 V.
reading.
Max. tightening torque: 45 Nm (33.1 lbf-ft)
44
Fault tracing the engine speed regulator

2. Undo the engine speed regulator connector.
3. Set multimeter 9510060-8 to resistance meas-
urement. Use the multimeter to measure the 5-
pin connector on the engine speed regulator, be-
tween:
Pin Resistance
1 - 2 app. 1.3 Ω
3 - 4 app. 25.4 Ω
3 - 5 app. 25.3 Ω
Fault tracing the starter motor

General
If battery voltage is below:
• 24.7 V (24 V system)
• 12.3 V (12 V system)
measured at the battery, the starter motor will not be
able to crank the engine at normal speed.
Voltage measurement, check
1. Check that battery voltage is at least 24.7 V or
12.3 V when not loaded, by measuring the bat-
tery terminals with multimeter 9510060-8.
2. Turn the main switch on.
3. Check that the voltage between positions 30
and 31 on the starter motor is the same as the
battery.
Carbon brushes
The specification for the carbon brushes in the start-
er motor is described below.
Carbon brush condition
New = 23 mm (0.90551")
Change at = 13 mm (0.51181")
45
Fault tracing the alternator

First remove the alternator, to make the measurement
points more accessible.
1. Prise off the plastic cover on the alternator with a
screwdriver.
2. Undo the four screws on the regulator.
3. Undo the two brush holder screws and remove the
brush holder and regulator.
46
Brushes
Measure the length of the brushes between the brush
mating surface and the brush holder. If the dimension
of the projecting part is less than 5 mm (0.20") , or if 5 mm (0,197 inch)
any brush is damaged, it should be changed.
NOTE! Make sure that the solder bead on the sol-
dered joint does not penetrate too far along the brush
lead. This would make the lead stiff, and could ob-
struct movement.
Regulator
Checking the regulator:
1. Use a multimeter set to diode measurement for
measuring.
2. Connect the measurement probes between the
brushes.
3. Switch the measurement probes over.
4. Check that no short circuit occurs in either case.
NOTE! If you suspect a regulator fault, it is easier to
install a new regulator on the alternator and test oper-
ate the charge system.
47
Checking the positive power diodes

1. Set the multimeter to diode measurement.
2. Connect the negative probe to B+ and the positive
probe to each one of the three stator windings in
turn.
3. Do the measurements on the three stator wind-
ings.
4. Switch the probe points over and do three new
measurements.
5. In one case, the instrument should indicate 400–
1200mV
(direction of current), and in the other case it
should indicate OL. The diodes block the current.
NOTE! The entire diode package is insulated from the
alternator frame.
48
Checking the negative power diodes

2. Connect the negative probe to B- and the positive
turn.
ings.
measurements.
1200mV
(direction of current), and in the other case it
should indicate OL. The diodes block the current.
NOTE! The entire diode package is insulated from the
alternator frame.
49
Checking the magnetizing diodes.

2. Connect the negative probe to D+ and the positive
turn.
ings.
measurements.
1200mV (direction of current), and in the other
case it should indicate OL.
50
Checking stator windings.

2. Connect the probe tips between the phase con-
nections.
3. Do three measurements.
4. The instrument should indicate the same value in
all three measurements.
Short circuit test on the stator

2. Connect the probe tips between the stator body
and one of the three stator windings.
3. The instrument should indicate OL. If it shows
any other value, the stator has a short circuit.
51
Checking the rotor

2. Connect the probe tips to the slip rings.
3. The instrument should give a hardly noticeable or
very weak reading.
4. At the same time, check that the slip rings do not
have any burn marks or other damage.
Short circuit test on rotor

2. Connect the probe tips between the stator body
and one of the three stator windings.
3. The instrument should indicate OL. If it shows
any other value, the stator has a short circuit.
52
Group 23 EDC 4 Electrical system
Electrical system
Warning! The battery locker must never be ex-
Important information about posed to open flames or electric sparks. Do not
electrical system smoke close to the batteries. The batteries gen-
erate hydrogen gas when charged, which forms
an explosive gas when mixed with air. This gas
Important! Stop the engine and cut the system is very flammable and highly explosive.
current with the main switch before doing any
work on the electrical system. Always use goggles when charging and handling
batteries.
1. Main switch
Battery electrolyte contains highly corrosive sulfuric
Never cut the circuit between the alternator and acid.
the batteries when the engine is running. The
If this comes into contact with your skin, wash at
main switch(es) must never be disconnected be-
once with soap and a lot of water. If you get battery
fore the engine has been stopped.
acid in your eyes, flush at once with a lot of water,
If the circuit is broken when the engine is running, and get medical assistance at once.
the voltage regulator can be destroyed and the al-
3. When starting with auxiliary batteries, please refer
ternator can be seriously damaged.
to “Starting with Auxiliary Batteries”.
The charging circuits must never be re-connected
4. Connection of auxiliary equipment
with the engine running, for the same reason. A
All auxiliary equipment must be connected to a
Volvo Penta charge splitter (optional) can be in-
separate junction box and fused.
stalled on the standard alternator to charge two
Extra current take-offs direct from the instrument
independent battery circuits.
panel should be avoided. The permissible extra
2. Batteries current take off must not exceed 5A in total (ap-
Never mix up the battery positive and negative plies to all instrument panels together).
poles when the batteries are installed.
Electric welding
If the batteries are wrongly connected, this can Remove the positive and negative cables from the
cause severe damage to the electrical equipment. batteries. Then disconnect all connections to the alter-
Please check the wiring diagram! The battery nator.
poles should be carefully cleaned, the terminals Disconnect the cable connectors from the control unit.
should always be tightened and thoroughly Please refer to “Control unit, changing”.
greased.
Always connect the welder earth clamp to the compo-
Avoid quick charging the batteries. If quick charg- nent to be welded, and as close as possible to the
ing has to be employed, the ordinary battery ca- weld site. The clamp must never be connected to the
bles must always be disconnected first. engine or in such a way that current can pass through
NOTE! Observe applicable safety rules when charg- a bearing.
ing batteries.
Important! When welding is finished, the dis-
During charging, the cell plugs should be loosened but connected components such as connectors, al-
remain in their holes. Ventilate well, especially if the ternator cables and battery cables must be re-
batteries are charged in an enclosed space. installed in the correct order.
Always switch off the charge current before undoing
the charging clamps.
53
Wiring diagram
Wiring diagrams, engine side
A. Speed regulator / Actuator
B. Coolant temperature sensor
C. Speed sensor, camshaft
D. Oil pressure sensor
E. Charge pressure sensor (two variants can
occur, 3-pin or 4-pin)
F. Fuel temperature sensor
G. Coolant level sensor
H. Air pre-heating relay (option)
J. Heating element (does not function without
the air pre-heating relay)
K. Battery (24/12 V).
L. Connector, air pre-heater/coolant level
Signal description, control unit, con-

nector “M”
#1. Earth (ground)
#2. Digital output signal
#3. Digital output signal 4
#4. Input signal 1, temperature NTC
#5. Input signal 2, temperature NTC
#6. Digital input signal 5
#7. Digital output signal 7 ”M”
#8. Earth (ground)
#9. Analogue input signal 3
#10. Earth (ground)
#11. Input signal, engine speed 2 Signal description, connector
#12. Earth (ground)
#13. Input signal, engine speed 1
Air pre-heater/coolant level (L)
#14. PWM output signal control solenoid #1. Coolant level (-)
(STG -) #2. Coolant level (+)
#15. PWM output signal control solenoid #3.
(STG +) #4. Ubatt (15+)
#16. Shielded cable #5. Earth (ground)
#17. Common connection for reference and #6. High voltage relay (-)
control rod measurement RF — #7. Coolant level (+)
#18. RF Ref #8. Output current (max 4 A)
#19. RF Meas.
#20. Earth (ground)
#22. + 5 V reference voltage
#23. Earth (ground)
#25. +5 V
54
Wiring diagram, control side

A. Engine speed potentiometer (throttle control)
B. CAN interface SAE J 1939
C. VODIA input
D. Droop contact
E. 1500 / 1800 rpm switch
F. Diagnostic connector
G. Tachometer
H. Warning lamp, oil pressure
J. Diagnostic lamp
K. Warning lamp, high coolant temperature
L. Fuse 15 A
M. Main switch
N. Battery (24/12 V).
”F”
Signal description, control unit, Signal description, connector,

connector “F” VODIA input (C)
#1. Ubatt (-) #1. Battery (+30)
#2. Earth (ground) #2. J1708A
#3. Digital output signal 2, warning lamp for #3. Battery (-)
coolant temperature #4.
#4. Digital output signal 5, diagnostic lamp #5. J1708B
#5. #6.
#6.
#7.
#8. J1708A
#9. J1708B
#10.
#11.
#12. CAN high
#13. CAN low
#14. Ubatt (+)
#15. Digital output signal 6, warning lamp for
oil pressure
#16. Digital output signal 8 (frequency)
tachometer
#17. Earth (ground)
#18. Digital input signal 1, 1500/1800 rpm
switch
#19.
#20.
#21. Digital input signal 2, droop contact
#22. Shielded cable
#23. Earth (ground) for SWG, potentiometer
#24. Analogue input signal 1, potentiometer
#25. + 5 V reference voltage, potentiometer
55
Notes
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AB Volvo Penta
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Workshop Manual: (Group 23) EDC 4

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Workshop Manual: (Group 23) EDC 4

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Workshop Manual

(Group 23) EDC 4

TD420VE, TAD420VE, TD520GE, TAD520GE,

Special tools ......................................................... 9 Fault codes .......................................................... 33

Technical data ..................................................... 10 Electrical fault finding ........................................ 39

Important Never use start spray or similar products as a

If work is done adjacent to a running engine, a

About the workshop manual Certified engines

Spare parts for electrical and fuel systems are subject

Damage, injury and/or costs of whatever nature,

Torque-angle tightening Sealants

Note. Loctite ® is a registered trademark of the Loctite Corpora-

999 9324 951 0060 951 2636

999 8482 3838619

Tools Designation – use 999 8482 Template, connector

Other special equipment

HDT-48-00 0411-310-1605 AMP 726 534 AMP 726 519

AMP 825 514 AMP 725 938 AMP 825 582

Deutsch connectors Blades and sockets 3.5 mm

825 514-1 Terminal crimping pliers AMP Connector (25-pin round)

Inductance, reference solenoid .............................. app. 13.3 mH (constant)

Speed sensor, camshaft

Coolant temperature sensor

Charge pressure sensor, 3 pin

Charge pressure sensor, 4 pin

* The resistance falls as the temperature rises.

Oil pressure sensor

Fuel temperature sensor

Type ...................................................................... NTC* (Negative Temperature Coefficient)

Air pre-heating (option)

* The resistance falls as the temperature rises.

Design and function

Summary Diagnostic function

Droop Smoke limiting

Control unit (EDC 4)

Speed sensor, camshaft (1)

Coolant temperature sensor, (3)

4-pin charge pressure sensor

The engines are delivered with either a 4-pin or a 3-pin

Oil pressure sensor (7)

Fuel temperature sensor (6)

Speed regulator / Actuator (2)

Electric heat pre-heating

1. Speed sensor, camshaft

* Only one type of sensor is used.

Warning lamp, oil pressure, lights up Engine is stopped

Min. value 0V Default value 0.1 V

Default value 4.6 V Max. value 5V

Maximum speed voltage error Setting idling speed

Min. value 0V Default value 700 r/min

Default value 4.9 V Max. value 4000 r/min

PID regulator P section Coolant temperature protection

Oil level protection

Read-only parameters Fine adjustment, engine speed

Use the VODIA tool (including Penta EDC4 software),

5. If the engine still runs badly and no other adjust-

Demanded engine speed

Demanded engine speed

True engine speed

True engine speed time

rpm Load removal

True engine speed

• Never undo the battery cables when the engine is running.