W Orkshop Manual

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Workshop Manual I
Group
Group 23 EM
E M S2 4(0)
TAD1640G
AD1640GE,
E, TAD1641G
TAD1641GE,
E, TAD1642G
TAD1642GE,
E,
TWD1643G
D1643GEE, T
TAD1641VE,
AD1641VE, TAD1642VE,
TAD1642VE,
TAD1643VE, TAD1650VE
TAD1650VE
EMS 2
TAD1640GE, T
TAD1641GE,
AD1641GE, T
TAD1642GE,
AD1642GE, TWD1643GE
TAD1641VE, T
TAD1642VE,
AD1642VE, T
TAD1643VE,
AD1643VE, T
TAD1650VE
AD1650VE
Contents
Safety Precautions ................................................. 2 Service procedures ............................................. 27
Introduction .......................................................... 2 When working with EMS 2 ................................. 27
Control module (EMS 2), replace ....................... 28
General information .............................................. 5 Unit injector, replacing ......................................... 29
About this Workshop Manual ............................... 5 Starting with auxiliary
auxiliary batteries
batteries .......................... 30
Spare parts .......................................................... 5
Certified engines .................................................. 5 Function check .................................................... 31
Diagnostic function for VODIA ........................... 31
Service procedures ............................................... 6
Our joint responsibility ...................
..........................................
....................... 6 Fault tracing ........................................................ 32
Tightening torques ............................................... 6 Symptoms and possible causes ........................ 32
Torque-angle tightening . .........................................
..................................... 7
Lock nuts ............................................................. 7 Diagnostic function .............................................. 33
Strength classes .................................................. 7 Malfunction message ......................................... 33
Sealant ................................................................ 7 Effect on engine .................................................. 33
Operation ............................................................ 34
General .................................................................. 8
Location of engine signs ...................................... 8 Fault codes (EMS 2) ............................................ 36
Tools ...................................................................... 9 Electrical fault tracing ......................................... 46

Special tools ........................................................ 9 General .............................................................. 46
Functional check of wiring and
Technical data ..................................................... 10 connector blocks ................................................ 46
Functional check of wiring and connector blocks 47
Design and function ............................................ 12 Splicing cables for cable connectors .................. 48
The EMS 2 system ............................................ 12 Checking/fault tracing components .................... 49
Component description, sensors and monitors ... 15
Control module (EMS
(EMS 2) ..................................... 18 Electrical system ................................................. 57
Control Interface Unit (CIU) ................................ 18 Important information - electrical system ........... 57
Unit injector ........................................................ 19 Electrical system, overview ............................... 68
Alternator ........................................................... 19 Wiring diagram EMS 2 ....................................... 60
Starter ................................................................ 19 Wiring diagram CIU ............................................ 61
Component location ........................................... 20 Wiring diagram DCU ........................................... 62
Limit values ......................................................... 21

Limit values, control module (EMS 2)
TAD1640–1642GE, TWD1643GE ....................... 21
Limit values, control module (EMS 2)
TAD1641–1643VE, TAD1650VE ........................ 23
Limp-Home function ........................................... 26
Group 23 EMS 2 Safety information
Safety information
information
Introduction If work is done adjacent to a running engine, a
careless movement or a dropped tool can lead
This workshop manual contains descriptions and re- to personal injury in the worst case. Be careful
pair instructions for the Volvo Penta products or prod- with hot surfaces (exhaust pipes, turbos, charge
uct versions noted in the table of contents. This work- air pipes, starting heaters etc.) and hot fluids in
shop manual should be used together with the work- pipes and hoses on an engine which is running
shop manual Technical data for the engine in ques- or which has just stopped.. Reinstall all guards
tion. Check that you have the correct Workshop removed during service operations before start-
Manual for your engine. ing the engine.
Read the appropriate safety precautions with care as
well as General information and Service proce- Check that the warning or information labels on
dures before starting work. the product are always clearly visible. Replace
labels which have been damaged or painted
over.
Important Never start the engine without installing the air

cleaner filter. The rotating compressor turbine in
In this book and on the engine you will find the follow- the turbocharger can cause severe injury. For-
ing special warning symbols. eign objects entering the intake ducts can also
WARNING! Possible danger of personal injury, cause mechanical damage.
extensive damage to property or serious me-
chanical malfunction if the instructions are not Never use start spray or similar products as a
followed. starting aid. They may cause an explosion in
the inlet manifold. Danger of personal injury.
IMPORTANT! Used to draw your attention to
something that can cause damage or malfunc- Only start the engine in a well- ventilated area.
tions on a product or damage to property. When operated in a confined space, exhaust
fumes and crankcase gases must be ventilated
NOTE: Used to draw your attention to important infor- from the engine bay or workshop area.
mation that will facilitate the work or operation in pro-
gress. Avoid opening the coolant filling cap when the
engine is hot. Steam or hot coolant can spray
To give you a perspective on the risks which always out and the system pressure will be lost. When
need to be observed and precautions which always needed, open the filler cap slowly and release
have to be taken, we have noted them below. the pressure in the system. Be very careful if a
stopcock or plug or engine coolant hose must
be removed when the engine is hot. It is difficult
Immobilize the engine by turning off the power to anticipate in which direction steam or hot
supply to the engine at the main switch coolant can spray out.
(switches) and lock it (them) turned off before
starting work. Set up a warning notice at the en- Hot oil can cause burns. Avoid skin contact with
gine control point. hot oil. Ensure that the lubrication system is not
under pressure before carrying out any work.
All service work should normally be done on a Never start or operate the engine with the oil fill-
stationary engine. Some tasks, such as adjust- er cap removed, otherwise oil could be ejected.
ments, need the engine running, however. Ap-
proaching an engine which is operating is a Stop the engine before carrying out operations
safety hazard. Remember that loose clothing or on the engine cooling system.
long hair can fasten in rotating parts and cause
serious personal injury.
If extra equipment is installed on the engine Most chemicals intended for the product e.g. en-
which alters its center of gravity a special lifting gine and transmission oils, glycol, petrol (gaso-
device is required to obtain the correct balance line) and diesel oil, or chemicals for workshop
for safe handling. use e.g. degreasers, paints and solvents are
hazardous. Read the instructions on the product
Never carry out work on an engine that is only packaging with care! Always follow the safety
suspended in ahoist. precautions for the product, i.e. use of protec-
tive mask, glasses, gloves etc. Make sure that
Never work alone when heavy components are other personnel are not inadvertently exposed to
to be dismantled, even when safe lifting devises hazardous chemicals, for example in the air. En-
such as lockable blocks & tackle are used. sure good ventilation in the work place. Follow
When using a lifting device two people are usu- the instructions provided when disposing of
ally required to do the work, one to take care of used or leftover chemicals.
the lifting device and another to ensure that
components are lifted clear and not damaged Exercise extreme care when leak detecting on
during the lifting operations. the fuel system and testing the fuel injector noz-
zles. Use eye protection. The jet which comes
Always check before starting work if there is from a fuel injector has very high pressure and
enough room to carry out removal work without considerable penetration power. Fuel can force
risking personal injury or damage to the engine its way deep into body tissue and cause severe
or parts. injury. Danger of blood poisoning (septicemia).
WARNING! The components in the electrical All fuels and many chemical substances are
system and in the fuel system on Volvo Penta flammable. Do not allow naked flame or sparks
products are designed and manufactured to min- in the vicinity. Petrol (gasoline), some thinners
imize the risk of fire and explosion. The engine and hydrogen gas from batteries are extremely
must not be run in areas where there are explo- flammable and explosive when mixed with air in
sive materials. the correct ratio. No Smoking! Ensure that the
work area is well ventilated and take the neces-
Only use the fuels recommended by Volvo Pen- sary safety precautions before starting welding
ta. Refer to the Instruction Book. Use of fuels or grinding work. Always ensure that there are
that are of a lower quality can damage the en- fire extinguishers at hand when work is being
gine. On a diesel engine poor quality fuel can carried out.
cause the engine to over-rev with resulting risk
of damage to the engine and personal injury. Ensure that rags soaked in oil or fuel and used
Poor fuel can also lead to higher service costs. fuel or oil filters are properly taken care of. Rags
soaked in oil can spontaneously ignite under
Remember the following when washing with a certain circumstances. Used fuel and oil filters
high pressure washer: Never direct the water jet are polluting waste and must be handed to an
at seals, rubber hoses, electrical components or approved waste management facility for de-
the radiator. struction, together with used lubrication oil, con-
taminated fuel, paint residue, solvents, degreas-
Always use protective glasses or goggles when ers and wash residue.
carrying out work where there is a risk of splin-
ters, grinding sparks, acid splashes or where Never expose a battery to naked flame or elec-
other chemicals are used. Your eyes are ex- trical sparks. Never smoke close to the batter-
tremely sensitive, injury could cause blindness! ies. The batteries generate hydrogen gas when
charged, which forms an explosive gas when
Avoid getting oil on your skin! Repeated expo- mixed with air. This gas is easily ignited and
sure to oil or exposure over a long period can re- highly explosive. A spark, which can be formed
sult in the skin being damaged. Irritation, dry- if the batteries are wrongly connected, is enough
ness and eczema and other skin problems can to make a battery explode and cause damage.
then occur. Used oil is more dangerous than Do not shift the connections when attempting to
fresh oil from a health aspect. Use protective start the engine (spark risk) and do not lean over
gloves and avoid oil soaked clothes and shop any of the batteries.
rags. Wash regularly, especially before eating.
There are special skin creams which counteract
drying out of the skin and make it easier to
clean off dirt after work is completed.
Always ensure that the Plus (positive) and Mi- The clutch must be adjusted with the engine
nus (negative) battery cables are correctly in- shut off.
stalled on the corresponding terminal posts on
the batteries. Incorrect installation can result in Use the lifting eyes fitted on the engine when
serious damage to the electrical equipment. Re- lifting the drive unit. Always check that the lift-
fer to the wiring diagram. ing equipment used is in good condition and has
the load capacity to lift the engine (engine
Always use protective goggles when charging weight including gearbox, if fitted, and any extra
and handling the batteries. Battery electrolyte equipment installed).
contains sulfuric acid which is highly corrosive.
Should the battery electrolyte come into contact Use an adjustable lifting beam or lifting beam
with unprotected skin wash off immediately us- specifically for the engine to raise the engine to
ing plenty of water and soap. If battery acid ensure safe handling and to avoid damaging en-
comes in contact with the eyes, immediately gine parts installed on the top of the engine. All
flush with plenty of water and obtain medical as- chains and cables should run parallel to each
sistance at once. other and as perpendicular as possible in rela-
tion to the top of the engine.
Turn the engine off and turn off the power at the
main switch(es) before carrying out work on the
electrical system.
© 2008 AB VOLVO PENTA

We reserve the right to make modifications without prior notice.
Printed on environmentally-friendly paper.
Group 23 EMS 2 General
General information
information
product in question will not be covered under any war-

About this Workshop Manual
Manual ranty or guarantee provided by AB Volvo Penta.
This Workshop Manual contains descriptions and in-
structions for the repair of standard versions of en-
gines: TAD1640GE, TAD1641GE, TAD1642GE, TWD1643GE,
Certified engines
TAD1641VE, TAD1642VE, TAD1643VE, TAD1650VE. The manufacturer warrants that both new and current-
The workshop manual can illustrate tasks done on ly operating engines that are certified to national and
any of the engines noted above. This means that the regional environmental regulations meet environmental
illustrations and photographs which clarify certain de- requirements. The product must correspond to the en-
tails might, in some cases, not correspond with other gine that was approved during certification. The follow-
engines. Repair methods are similar in all important ing requirements for service and spare parts must be
respects, however. The Engine Designation and En- complied with, for Volvo Penta as a manufacturer to
gine Numbers can be found on the product plate. See be responsible for ensuring that engines in use com-
”Technical data TAD1640GE, TAD1641GE, ply with the stipulated environmental requirements:
TAD1642GE, TWD1643GE, TAD1641VE,
TAD1642VE, TAD1643VE, TAD1650VE”.
Please always include both the engine designation
• Service and maintenance intervals recommended
by Volvo Penta must be followed.
and the engine serial number in all correspondence.
The Workshop Manual is produced primarily for the
use of Volvo Penta workshops and service techni-
• Only Volvo Penta Original Spare Parts intended
for the certified engine version may be used.
cians. For this reason the manual presupposes a cer-
tain basic knowledge and that the user can carry out
the mechanical/electrical work described to a general • Service work that covers injection pumps, pump
settings, and injectors must always be carried out
standard of engineering competence.
by an authorized Volvo Penta workshop.
Volvo Penta constantly improves its products, so we
reserve the right to make modifications without prior
notification. All information in this manual is based on • The engine must not be converted or modified in
any way, except for the accessories and service
product data which was available up to the date on
kits which Volvo Penta has approved for the en-
which the manual was printed. Any material changes
gine.
introduced into the product or service methods after
this date are notified by means of Service Bulletins.
• Any seals on the engine may not be broken by
unauthorized persons.
IMPORTANT! When spare parts are needed,

Spare parts use only Volvo Penta Original Spares.
Spare parts for the electrical and fuel systems are Use of non-original parts will result in AB
subject to various national safety requirements. Volvo Volvo Penta being unable to warrant that
Penta Original Spare Parts meet these specifications. the engine corresponds to the certificated en-
Any type of damage which is the result of using spare gine version.
parts that are not original Volvo Penta parts for the
Any damage, injury and/or costs which arise
due to the use of non-original Volvo Penta
spares for the product in question will not be
compensated by Volvo Penta.
Group 23 EMS 2 Repair instructions
Repair instructions
The working methods described in the Workshop Man-
ual apply to work carried out in a workshop. The en-
Our common responsibility
gine has been removed and is installed in an engine Each engine consists of a large number of collaborat-
fixture. Unless otherwise stated reconditioning work ing systems and components. Any deviation of a
which can be carried out with the engine in place fol- component from its technical specification can dra-
lows the same working method. matically increase the environmental impact of an oth-
See chapter ”Safety information” where the meaning erwise good engine. For this reason, it is extremely
of the warning signs used in the manual are explained important that specified wear tolerances are main-
in detail. tained, that systems with adjustment facilities are cor-
rectly adjusted and that Volvo Penta Original Spares
are used for the engine. The stated service intervals
WARNING! in the Maintenance Schedule must be observed.
Some systems, such as the components in the fuel
IMPORTANT! system, require special expertise and special testing
equipment for service and maintenance. Some com-
NOTE: ponents are sealed at the factory, for environmental
reasons etc. Under no circumstances attempt to ser-
are not comprehensive in any way, since we can not
vice or repair a sealed component unless the service
of course foresee everything, because service work is
technician carrying out the work is authorized to do
done in highly varying circumstances. For this reason,
so.
all we can do is to point out the risks which we believe
could occur due to incorrect work in a well-equipped Remember that most chemical products,
workshop, using work methods and tools tested by incorrectly used, damage the environment. Volvo Pen-
us. ta recommends the use of bio-degradable degreasing
agents for all cleaning of engine components unless
All operations described in the Workshop Manual for otherwise stated in the Workshop Manual. Pay special
which there are Volvo Penta Special Tools available attention to make sure that oils and washing residue
assume that these tools are used when carrying out etc are handled correctly for destruction, and do not
the repair. Volvo Penta Special Tools have been spe- unintentionally end up in nature.
cifically developed to ensure the most safe and ratio-
nal working methods possible. It is therefore the re-
sponsibility of anyone using other tools or other work-
ing methods than we recommend to determine that
Torque
there is no risk of personal injury or mechanical dam- The tightening torques for critical joints, which should
age or malfunction as a result. be tightened with a torque wrench, are listed in Tech-
In some cases special safety precautions and user in- nical data,Tightening Torques”, and are noted in the
structions may be required in order to use the tools task descriptions in the manual. All torque specifica-
and chemicals mentioned in the Workshop Manual. tions apply to clean screws, screw heads and mating
These rules must always be observed, so there are no faces. Torque data stated apply to lightly oiled or dry
special instructions about this in the workshop manu- threads. Where grease, locking or sealing agents are
al. required for screwed joints this is stated in both the
operation description and in ”Tightening Torques”.
By following these basic recommendations and using Where no torque is stated for a joint use the general
common sense it is possible to avoid most of the torque shown in the following table. The torques stat-
risks involved in the work. A clean work place and a ed are a guide and the joint does not have to be tight-
clean engine will eliminate many risks of personal inju- ened using a torque wrench.
ry and engine malfunction.
Especially when working on the fuel system, engine Dimension Tightening torque
lubrication system, air intake system, turbocharger
unit, bearing seals and seals, it is extremely important Nm lbf.ft.
to avoid dirt or foreign objects entering the parts or M5 6 4.4
systems, since this can result in reduced service life
M6 10 7.4
or malfunctions.
M8 25 18.4
M10 50 36.9
36 .9
M12 80 59.0
59 .0
M14 1400
14 103.3
Tor
orque-angle
que-angle tightening Sealant
In torque/angle tightening, the fastener is tightened to Several types of sealant and locking liquid are used
the specified torque, and tightening then continues on the engines. The properties of the sealants differ
through a pre-determined angle. Example: for 90° an- as they are intended for different strengths of fasten-
gle tightening, the joint is turned a further 1/4 turn in ings, temperature, resistance to oil and other chemi-
one sequence, after the specified tightening torque cals, and also for different materials and gap thick-
has been achieved. nesses found in the engine.
To ensure service work is correctly carried out it is im-
portant that the correct sealant and locking fluid type
is used on the joint where the agents are required.
Lock nuts In this Volvo Penta Workshop Manual the user will
find that each section where these agents are applied
Disassembled locknuts shall not be re-used, they in production states which type was used on the en-
shall be replaced by new ones, since the locking prop- gine.
erties are impaired or lost when the nut is used sever-
For service work, an similar product from the same
al times. For lock nuts with a plastic insert such as
manufacturer, or corresponding product with the same
Nylock ® the torque stated in the table is reduced if the
characteristics from another manufacturer, can be
Nylock ® nut has the same head height as a standard
used.
hexagonal nut without plastic insert. Reduce the
torque by 25% for screw size 8 mm or larger. Where When using sealants and locking fluids, make sure
Nylock ® nuts are higher, where the metallic thread is that mating surfaces are dry and free from oil, grease,
of the same height as a standard hexagonal nut, the paint, anti-corrosion agent and old sealant. Always fol-
torques given in the as shown in table apply. low the manufacturer’s instructions for use regarding
temperature range, curing time and any other instruc-
tions for the product
Two different basic types of agent are used on the en-
gine. These are:
Strength classes 1. RTV agent (Room Temperature Vulcanizing). Used
Screws and nuts are sub-divided into different for gaskets, sealing gasket joints or coating gaskets.
strength classes. The classification is shown by a RTV is visible when a part has been disassembled;
marking on the screw head. Markings of a higher num- old RTV must be removed before resealing the joint.
ber indicate stronger material. For example, a screw The following agents are of RTV-type: Loctite® 574,
marked 10-9 is stronger than one marked 8-8. For this Volvo Penta 840879-1, Permatex® No. 3, Volvo Pen-
reason, it is important when fasteners are dismantled, ta 1161099-5, Permatex® No 77. Old sealant can be
that the screws are put back in the correct places removed using denatured alcohol in all cases.
when they are re-installed. If a bolt must be replaced
check in the spare parts catalogue to make sure the 2. Anaerobic agents. These agents cure in the
correct type is used. absence of air. These agents are used when two solid
components, i.e. cast components, 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 preparations are colored to make
them visible. Cured anaerobic agents are extremely
resistant to solvents and the old agent cannot be re-
moved. When reinstalling the part, degrease it careful-
ly and then apply new sealant.
The following agents are anaerobic: Loctite® 572
(white), Loctite® 241 (blue).
Notice: Loctite® is a registered trademark for the Loctite Corpo-
ration.
Permatex® is a registered trademark for the Permatex Corpora-
tion.
Group 23 EMS 2 General
General
Location of engine signs
The sign above shows:

1 Engine designation
2 Serial number
3 Specification number
The sign above shows:

A Engine designation
B Engine power, net (without fan)
C Max. engine speed
D Main software
E Data set 1
F Data set 2
G Product number
Explanation of engine designation:

E.g. TAD1641GE/TAD1641VE
T – Turbo
A – Air to air intercooler
D – Diesel engine
16 – Cylinder volume, liter
4 – Generation
1 – Version
G – Generator unit engine
V – Stationary and mobile operation
E – Emission certified
Group 23 EMS 2 Tools
Tools
Special tools
The following special tools are used when working on the engine. The special tools can be ordered from AB Volvo
Penta by specifying the number shown.
951 2636 999 8482 999 8534
999 8567 999 8699 999 9324
951 0060 3838619 874427
Tool Designation – use

951 2636 Pin tool, connector 999 9324 Cable lug crimper, repair
999 8482 Gauge, connector block 951 0060 Multimeter, fault tracing/checking
1078054 Repair kit (not shown in figure)
999 8534 4-pin adapter, diagnostics 3838619 VODIA, complete with cable harness.
999 8567 7-pin adapter, diagnostics See ”VODIA User´s Guide” for ordering
999 8699 62-pin adapter, diagnostics separate parts.
874427 Nozzle diagnostic output
Group 23 EMS 2 Technical data
Control unit
Technical data
Volt
Voltage
age .................................................................. 24 V
Connector .............................................................. 2 x 62-pin
Working temperature range .................................... -40°C to +90°C (-40°F to +194°F)
Cooling ................................................................... Exter
External
nal fuel cooling
Sensor, water in fuel

Volt
Voltage
age .................................................................. 24 V
Connector .............................................................. 2-pin
Connector type
type ....................................................... Closing in presence of water
Sensor, fuel pressure

Volt
Voltage
age .................................................................. 5 V
Connector .............................................................. 3-pin
Working pressure range ..... .........................................
.................................... 0–700 kPa (0–101.5 Psi)
Pressure signal
signal ...................................................... 0,5–4.5 V
Type ...................................................................... Linear
Max tightening torque ............................................. 30 ± 5 Nm (22.13 ± 3.688 lbf ft)
Camshaft sensor/flywheel sensor

Inductive sensor
Connector .............................................................. 2-pin
Type ...................................................................... Inductive sensor
Sensor, oil pressure

Volt
Voltage
age .................................................................. 5 V
Connector .............................................................. 4-pin
.................................... 0–700 kPa (0–101.5 Psi)
Pressure signal
signal ...................................................... 0,5–4.5 V
Working temperature range: ................................... -40°C till +140°C
Type ...................................................................... Linear
Combined sensor, oil level/oil temperature

Connector .............................................................. 4-pin
Contact type
type .......................................................... Resistive/NTC
Max tightening torque ............................................. 7 Nm (5.2 lbf-ft)
Combination sensor, charge air pressure/charge air temperature

Volt
Voltage
age .................................................................. 5 V
Connector .............................................................. 4-pin
.................................... 40–400 Pa (5.8–58 Psi)
Pressure signal ...................................................... 0.3–4.8 V
Working temperature range .................................... -40°C till +130°C (-40°F to +266°F)
Type ...................................................................... Linear/NTC
Max tightening torque ............................................. 4.5 Nm (33.1 lbf-ft)
10
Group 23 EMS 2 Technical data
Sensor, coolant temperature

Volt
Voltage
age .................................................................. 5 V
Connector .............................................................. 2- 2-ppin
Type ...................................................................... NTC
Max tightening torque ............................................. 20-24 Nm (14.75 - 17.7 lbf-ft)
Sensor, coolant level

Connector .............................................................. 2-
2-ppin
Contact type .......................................................... Closing with low coolant level
Sensor, crankcase pressure

Volt
Voltage
age .................................................................. 5 V
Connector .............................................................. 3- 3-ppin
Working pressure range ......................................... 0–700 kPa (0–101.5 Psi)
Pressure signal
signal ...................................................... 0,5–4.5 V
Type ...................................................................... Linear
Sensor, piston coolant pressure

Volt
Voltage
age .................................................................. 24 V
Connector .............................................................. 2- 2-ppin
Pressure signal ...................................................... At 150 kPa ±20 kPa (21.76 ±2.9 psi)
Type ...................................................................... Two-position (NC)
Combined air filter pressure and temperature sensor

Volt
Voltage
age .................................................................. 24 V
Connector .............................................................. 4- 4-ppin
Pressure signal ...................................................... At 5 kPa ±0.5 kPa (0.725 ±0.0725 Psi)
Working temperature range .................................... -40°C till +130°C (-40°F to +266°F)
Type ...................................................................... Linear/Two-position (NC)
Unit injector
Volt
Vo ltage
age .................................................................. 90 V
Connector .............................................................. 2- 2-ppin
Injection pressure...................................................
pressure ................................................... 180 kPa (26.11
(26.11 Psi)
Alternator
Volt
Voltage
age .................................................................. 24 V
Connector .............................................................. 2-2-ppin
Capacity ................................................................ 80 A (110 A optional)
Starter
Volt
Vo ltage
age .................................................................. 24 V
Connector .............................................................. 2- 2-ppin
Capacity ................................................................ 7 kW
11
Group 23 EMS 2 Design and function
Design and function

The EMS 2-system
EMS 2 stands for ”Engine Management System” and is an electronic system with CAN communications (Control-
ler Area Network) for control of diesel engines. The system has been developed by Volvo Penta and includes fuel
control and diagnostic function. The system consists of a control module, six unit injectors, a number of sensors
that supply the control module with measurements, sockets for diagnosis and functional checks. The engine is
connected to a communications interface consisting of a CAN link and a serial link.
CAN (Controller Area Network) DCU (Display Control Unit)

The CAN J1939 link handles all communications be- DCU is a digital instrument panel that communicates
tween the engine control module EMS 2 and a com- with the engine control module via the CAN link. DCU
munications interface such as the CIU or DCU, in ad- has several functions, such as:
dition to the diagnostics that are handled by the so
Controlling the engine
called J1708/J1587 link. The CAN link is much faster
than the J1708/J1587 link. The CAN link has been – Start, stop, controlling rpm, control mode isochro-
prepared to connect to other components with SAE nous/speed drop, pre-heating.
J1939 protocol such as instrument panels and trans- Monitoring
missions.
– rpm, charge pressure, charge temperature, cool-
If, for some reason, a fault develops on the CAN link, ant temperature, oil pressure, oil temperature, en-
signals for the rpm-potentiometer and the start and gine hours, battery voltage, instantaneous fuel
stop knobs are taken over by the J1708/J1587 link. consumption and fuel consumption (trip fuel).
However, instrument and indicator lamps are com-
pletely turned off. If faults develop on both links, the Diagnostics
GE engines maintain the same rpm while VE engines – Shows fault codes as text. Lists previous faults.
slow to idle. The only way to shut off the engine in
this case is to use the auxiliary stop (AUX-STOP) Setting parameters
placed on the engine’s left side. – Idling speed, pre-heating when ignition on, lamp
CIU (Control Interface Unit) test, alarm limit for oil temperature/coolant tem-
perature, control mode, control gradient (VE), pri-
The CIU is a ”translator” between the CAN bus and mary engine rpm (GE), speed drop (GE), engine
the customer’s own control panel. This unit has two overspeed limit (GE), engine cut off, overspeed
serial communication links, one fast and one slow. (GE).
The fast one is a CAN link that features a bus speed
of 250 Kbit/s. All data regarding instruments, indicator
lamps, contacts and potentiometers are controlled by
this bus. The slower J1708/J1587 link handles diag-
nostic information for, among other things, the flash-
ing code. The diagnosis tool VODIA also uses the
J1708/J1587 link to communicate with the system.
DU (Display Unit)
DU is an instrument that displays the engine’s opera-
ting values. Measurement values are shown graphical-
ly on an LCD screen. The display communicates via
the CAN link and consists of a computerized unit for
fixed installation in a control panel.
You are connected to the CAN link between the engi-
ne control module and CIU or DCU.
12
Input signals Output signals

The control module receives input signals about the Based on the input signals the control module controls
engines operating conditions and other things from the the following components:
following components:
– the unit injectors
– coolant temperature sensor
– starter motor
– charge pressure / charge temperature sensor
– alternator
– crankcase pressure sensor
– main relay
– position sensor, camshaft – pre-heating relay
– speed sensor, flywheel
The information from the sensors give exact data
– piston cooling pressure sensor about prevailing operating conditions and allows the
– coolant level sensor processor in the control module to, among other
things, calculate correct injection amount, injection
– oil pressure sensor timing and check the engine’s condition.
– oil level sensor and oil temperature sensor
– fuel pressure sensor
– water in fuel indicator
– air filter pressure
– air temperature sensor
Diagnosis
Engine speed Cooling water temperature
Accelerator setting Boost air temperature
Piston cooling pressure Air temperature

Water in fuel Electronic Boost air pressure
Air filter pressure control Oil temperature
Oil level module Oil pressure
Camshaft position Crankcase pressure
Coolant level Fuel pressure
Fuel Injection
quantity timing
13
Fuel control Cylinder balancing

The engine’s fuel requirement is analyzed up to 100 When idling, the control module can supply the cylin-
times per second (depending on engine rpm). The en- der with different amounts of fuel. This so the engine
gine’s injection amount and injection timing is con- will have a more even idle. At higher rpm, this problem
trolled electronically via fuel valves on the unit injec- does not exist, and the cylinders receive the same
tors. amount of fuel.
This means that the engine always receives the cor-
rect volume of fuel in all operating conditions, which
offers lower fuel consumption, minimal exhaust emis- Altitude correction
sions etc. The control module is equipped with an atmospheric
The control module checks and controls the unit injec- air pressure sensor and altitude correction function for
tors so that the correct amount of fuel is injected into engines that operate at a high altitude. This function
each cylinder. It calculates and sets the injection an- limits amount of fuel depending on ambient air
gle. The control is primarily performed using the speed pressure.The control module is equipped with an at-
sensors and the combined sensor for boost pressure/ mospheric air pressure sensor and altitude correction
charge air temperature. function for engines that operate at a high altitude.
This is to prevent smoke, high exhaust temperature
The control module affects the unit injectors via an and to protect the turbocharger from over-speeding.
electronic signal to the unit injectors’ electromagnetic
fuel valve, which can open and close.
When the fuel valve is open, fuel flows past, through
the unit injectors’ holes and continuing out through the Diagnostic function
fuel channel. Fuel is not sprayed into the cylinder in The task of the diagnosis function is to detect and lo-
this position. cate disturbances within the EMS 2 system, to pro-
When the fuel valve closes, pressure starts to build tect the engine, and to provide information about prob-
from the unit injector’s mechanically operated pump lems that have developed.
plunger. When sufficient pressure has developed, fuel If a malfunction is discovered, this is announced by
is injected into the cylinder via the unit injector’s injec- warning lamps, a flashing diagnostic lamp or in plain
tor section. language on the instrument panel, depending on the
The fuel valve is re-opened and pressure in the unit equipment used. If a fault code is obtained as a flash-
injector decreases at the same time as the fuel injec- ing code or in plain language, this is used for guidance
tion to the cylinder stops. in any troubleshooting. Fault codes can also be read
In order to determine when the fuel valve shall open or by Volvo’s VODIA tool at authorized Volvo Penta
close, the control module has access to signals from workshops.
sensors and switch contacts. In case of serious disturbances, the engine is shut
down completely or the control module reduces the
available power (depending on the application). Once
again, a fault code is set for guidance in any trouble-
Calculating amount of fuel shooting.
The amount of fuel that is sprayed into a cylinder is
calculated by the control module. The calculation de-
termines the time that the fuel valve is closed (when
the fuel valve is closed fuel is sprayed into the cylin-
der). The parameters controlling injected amount of
fuel are:
• Rpm requested
• Engine protector functions
• Temperature
• Charge air pressure
14
Component description
The numbers after the heading refer to ”component lo-
cation” on page. 20.
Sensor,, water in fuel (11)

Sensor
The sensor is located in the lower part of the fuel pre-
filter.
It’s purpose is to detect water in the fuel system. The
sensor comprises two copper electrodes, between
which the resistance is measured. When the resis-
tance drops below a certain limit, which indicates that
there is water in the fuel, a warning message is sent
to the control unit.
Position sensor,
sensor, camshaft (15)
The position sensor is located in the upper timing gear
cover. The camshaft position sensor is of the induc-
tive-sensor type. The sensor reads off a cogged wheel
with 7 cogs. The impulses from the camshaft sensor
give the control unit information about which cylinder
is in turn for injection and when it is performed.
Oil pressure sensor (9)

The oil pressure and temperature are measured by a
combined sensor located on the left side of the en-
gine, next to the control unit.
The sensor is fitted in the engine block so that mea-
surements are performed in the lubrication systems
main oil galley. The pressure signal is a voltage signal
proportional to the pressure. The sensor reference
voltage is 5 Volts.
Speed sensor,
sensor, flywheel (18)
The sensor is located in the left side of the flywheel
housing.
The flywheel speed sensor is of the inductive type. It
reads off the crankshaft position and speed from
grooves in the flywheel. The signal is sent to the con-
trol unit, which calculates injection timing and fuel
quantity.
15
Charge air pressure/charge air

sensor (3)
The charge air pressure and temperature are mea-
sured via a combined sensor positioned on the inlet
pipe.
The charge air pressure sensor measures absolute
pressure, which is the sum of charge air pressure and
atmospheric pressure. The sensor supplies the control
unit with a voltage signal proportional to the absolute
pressure. The sensor receives a reference signal of 5
Volts from the control unit.
The charge air temperature sensor comprises a non-
linear resistor, where the resistance is dependant on
the temperature of the resistor body. The resistance
drops as temperature rises.
Coolant temperature sensor (16)

The sensor is located in the left rear part of the cylin-
der head.
The sensor senses the coolant temperature and
sends the information to the control unit. The sensor
comprises a non-linear resistor, where the resistance
is dependant on the temperature of the resistor body.
The resistance drops as temperature rises.
Fuel pressure sensor (10)

The sensor is located on the left side of the engine,
mounted on the fuel filter bracket.
The pressure signal is a voltage signal proportional to
the pressure. The sensor reference voltage is 5 Volts.
Coolant level sensor (1)

The sensor is located in the expansion tank.
It’s purpose is to detect if the coolant level in the cool-
ing system (expansion tank) becomes too low. The
sensor is a magnetically sensitive switch. A float lo-
cated around the sensor affects the switch differently
depending on the coolant level. A alarm signal is sent
when the coolant level is too low.
16
Oil level sensor / oil temperature

sensor (12)
The sensor is located in the oil sump.
The purpose of the level sensor is to detect if the oil
level becomes too low. A current is passed through
the sensor and the voltage measured across it is then
proportional to the oil level. A alarm signal is sent
when the oil level is too low. The temperature sensor
consists of a non-linear resistor, where the resistance
is dependent on the temperature of the resistor body.
The resistance drops as temperature rises.
Crankcase pressure sensor (13)

The sensor is located on top of the engine in the mid-
dle of the valve cover on the engine’s left side.
Piston cooling pressure sensor (17)

The monitor is installed on the engine block below the
turbo on the right side of the engine.
Air filter pressure sensor / air filter

temperature sensor (4)
Air filter pressure and air filter temperature are mea-
sured by a combined sensor placed above the air fil-
ter.
The air filter pressure sensor measures absolute pres-
sure, the sum of air filter pressure and atmospheric
pressure. The sensor consists of a monitor that sends
a signal to the control module when the pressure in
the air filter becomes too high.
The air filter temperature sensor consists of a non-lin-
ear resistor, where the resistance is dependant on the
temperature of the resistor body. The resistance drops
as temperature rises.
17
Control module EMS 2

The control module checks and controls the unit injec-
tors so that the correct amount of fuel is injected into
each cylinder. It calculates and sets the injection an-
gle. The control is primarily performed using the speed
sensors and the combined sensor for boost pressure/
charge air temperature.
The EMS 2 system processor is located in the control
unit, where it is protected from moisture and vibration.
The processor receives information continuously
about:
• engine speed
• camshaft position
• charge air pressure

• charge air temperature
• coolant temperature
• oil pressure
• oil temperature
• oil level
• crankcase pressure
• piston cooling pressure
• water in fuel
• fuel pressure
• coolant level
• air filter pressure
• air filter temperature

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.
Control Interface Unit (CIU)

CIU is a control unit that handles all interactions with
the operator.
It communicates with the engine via two serial com-
munication buses. J1939 is used for control and moni-
toring of the engine. J1587 is used for diagnostics and
backup.
The CIU unit reads in the status of a number of
switches as well as the engine speed request and for-
wards them to the engine. It also controls the four an-
alog instruments and up to nine
warning lamps. By using the diagnostic button and a
diagnostic lamp, the driver can read off fault codes
from the system.
18
Unit injector
The unit injectors are located under the valve cover,
mounted in the cylinder head.
The engine’s fuel requirement is analyzed up to 100
times per second (depending on engine rpm). The
amount of fuel injected into the engine and the injec-
tion timing are electronically controlled via the unit in-
jector’s solenoid controlled fuel valves. This means
that the engine always receives the correct volume of
fuel in all operating conditions, which offers lower fuel
consumption, minimal exhaust emissions etc.
Alternator
The alternator is belt driven and is located at the left
front of the engine.
The alternator’s voltage regulator is equipped with a
sensor system. The sensor system compares the
charging voltage between the alternator’s B+ and B-
terminals, with the voltage between the battery’s posi-
tive and negative poles. The voltage regulator then
compensates the voltage drop in the cables between
the alternator and battery by increasing the charging
voltage at the alternator, if necessary.
Starter
The starter is mounted on the flywheel housing on the
engine’s right side.
During starting, a gear on the starter rotor shaft is
moved axially so that it engages with the ring gear on
the engine’s flywheel. The axial movement as well as
the activation of the starter is controlled by a solenoid
on the starter motor.
The starter solenoid in turn is connected via the start-
er relay, which is activated when the starter key is
turned to position III/the starter button is pressed.
19
Component location
1. Coolant level sensor (in the expansion tank)

2. Extra stop
3. Charge pressure / charge temperature sensor
4. Air filter pressure sensor and air temperature sen-
sor
5. Main circuit breaker 10 A
6. Connector block interface (8 pin contact)
7. Main relay
8. Diagnostic connector (2-pin connector)
9. Oil pressure sensor
10.. Fuel pressure sensor
10
11.. Sensor, water in fuel
11
12.. Oil level and oil temperature sensor (installed in-
12
side the oil pan)
13.. Crankcase pressure sensor
13
14. Air pre-heater with pre-heating relay
15.. Camshaft position sensor
15
16. Coolant temperature sensor
17.. Piston cooling pressure sensor
17
18.. Flywheel position and speed sensor
18
20
Group 23 EMS 2 Limit values
Limit values
values
Limit values,
values, control module (EMS 2) TAD1640–1642GE, TWD1643GE
Oil temperature
NOTE: The engine protection can be turned off.
Preset alarm limit Adjustable between Alarm lamp is lit Engine cut off
125 °C (257 °F) 120 - 130 °C at alarm limit +5 °C (+41 °F)
(248 - 266 °F)
Oil pressure
idle: 160 kPa (23,21 Psi) not adjustable at alarm limit 130 kPa (18,85 Psi)
1500 rpm: 250 kPa not adjustable at alarm limit 220 kPa (31,91 Psi)
(36,26 Psi)
1800 rpm: 300 kPa not adjustable at alarm limit 270 kPa (39,16 Psi)
(43,51 Psi)
Oil level
low oil level
level not adjustable low oil level no
Coolant temperature
98 °C (208 °F) 95 -103 °C at alarm limit +5 °C (+41 °F)
(203 - 217,4 °F)
Coolant level
low coolant level not adjustable low coolant level low coolant level
21
Fuel pressure
See diagram, fuel not adjustable at alarm limit no
pressure below
Fuel pressure
Water in fuel
water in fuel not adjustable water in fuel no
Crankcase pressure
increasing pressure not adjustable increasing pressure increasing pressure
Boost air temperature

80 °C (176 °F) not adjustable at alarm limit +5 °C (+41 °F)
Boost air pressure

390 kPa (56,56 Psi) not adjustable at alarm limit +10 kPa (+ 1,45 Psi)
RPM
NOTE: Engine safety device may be put on.
20 % above
above normal
normal rpm 0 - 20 % at alarm limit no
22
Limit values, contr

control
ol module (EMS 2) TAD1641–1643VE, TAD1650VE
Oil temperature
Preset alarm limit Adjustable between Alarm lamp is lit Torque limitation Engine cut off
125 °C (257 °F) 120 - 130 °C at alarm limit no +5 °C (+41 °F)
(248 - 266 °F)
Oil pressure
See diagram oil pressure not adjustable at alarm limit max 900 Nm -30 kPa (-4,35 Psi)
below. (664 lbf-ft) at
alarm limit
Oil pressure
Oil level
low oil level not adjustable low oil level no no
Coolant temperature
98 °C (208 °F) 95 -103 °C at alarm limit no +5 °C (+41 °F)
(203 - 217,4 °F)
23
Coolant level
low coolant level not adjustable low coolant level no no
Fuel pressure
See diagram, fuel not adjustable at alarm limit no no
pressure below.
Fuel pres-
sure
Water in fuel
water in fuel not adjustable water in fuel no no
Crankcase pressure
increasing pressure not adjustable increasing no with increasing
pressure pressure
24
Boost air temperature

80 °C (176 °F) not adjustable at alarm limit no +5 °C (+41 °F)
Boost air pressure

390 kPa (56,56 Psi) not adjustable at alarm limit no +10 kPa (+ 1,45 Psi)
RPM
NOTE: Engine safety device may be put on.
20 % above normal rpm 0 - 20 % at alarm limit no no
25
Limp-home value
(emergency regulation value)
The basic value is used by the control unit in order to
continue running the engine when a technical fault oc-
curs in the system or it’s peripherals, sensors etc.
The following value (Limp home-value) is stored in the
control unit:
Boost air temperature +40 °C (+104 °F)
Coolant temperature -15 °C (+5 °F)
Boost air pressure See diagram below
Engine speed rpm is frozen
Charge air pressure GE Charge air pressure VE
26
Repair instructions
When working with EMS 2 system
Follow the instructions below so as not to damage the EMS 2-system control unit:
• Never switch off main power while the engine is running.
• Never disconnect a battery cable while the engine is running.
• When fast charging the batteries, turn off the main switch or disconnect one of the battery cables.
The main switch does not need to be turned off during normal charging.
• Only batteries may be used for starting assistance. Starting boosters can generate excessive voltages and
damage the control units.
• Disconnect power to the EMS 2-system before removing the two 62-pin connectors from the control unit.
• If damage to the cable harness is detected, the 62-pin connectors on the control unit must be removed.
IMPORTANT! Disconnect the 62-pin connectors from the control unit if you are about to perform welding.
• Make sure that the connector pins are not contaminated with oil or
other liquids while disconnected.
Otherwise a contact problem may arise or the oil may run down inside to the pressure sensitive membrane
and cause a misreading.
27
Control module (EMS 2),

replace
WARNING! Exchange of control units between
engines, during fault tracing or repair, must nev-
er be performed under any circumstances..
1. Clean thoroughly around the control module fuel

connections.
2. Remove electricity from the engine by discon-

necting the negative battery terminal.
3. Remove the lower part of the crankcase ventila-

tion pipe.
4. Remove upper and lower cable harnesses

clamps.
5. Remove the control module’s cable harness by

moving the connector block’s retaining clips
outwards.
6. Remove upper and lower fuel connections with

the cooling element, plug the fuel lines.
7. Remove the screws that hold the control mod-

ule and remove the control module.
8. Transfer the cooling element to the new control

module. Make sure that the surface between
the cooling element and the control module is
clean.
9. Install the new control module. Torque as

specified in Technical data.
10..
10 Install upper and lower fuel connections to the
cooling element with new sealing washers.
11..
11 Install the cable harness and clamps.
12..
12 Install the lower crankcase ventilation pipe.
13..
13 Vent the fuel system, see Fuel System, bleed-
ing. Start the engine and check for error codes.
28
Unit injector,
injector, replacing
For replacement of unit injectors see:
”Workshop Manual Group 21-26 Industrial engine
TAD1640GE,TAD1641GE,TAD1642GE,TWD1643GE,
TAD1641VE,TAD1642VE,TAD1643VE,TAD1650VE”
When a unit injector has been replaced, a new injector
code must be programmed into the EMS 2-control
unit. This is done with the VODIA tool.
Each unit injector has a unique code. The injector
code, which comprises six characters, is stamped on
the unit injector as a hexadecimal code.
In the illustration to the right, the injector code is
5D008A.
29
Starting with auxiliary

batteries
WARNING! Ventilate well. Batteries can gener-
ate oxy-hydrogen, which is very flammable and
highly explosive. A short circuit, open flame or
spark could cause a violent explosion.
WARNING! Never mix up the battery cables po-

sitions on the battery. Mixing up the battery ter-
minals when applying starting assistance can
cause a short circuit and sparks, which could
cause an explosion and also damage the en-
gine’s electrical components.
1. Check that the auxiliary battery’s voltage is the
same as the engine’s system voltage.
2. First connect the red (+) jump lead to the dis-
charged battery’s positive terminal (+) and then
to the auxiliary battery’s positive terminal (+).
3. Then connect the black (-) jump lead to the auxil-
iary battery’s negative terminal (-) and to a suit-
able ground somewhere away from the dis-
charged battery’s negative terminal (-) e.g. to
the negative cable on the starter motor.
WARNING! The black (-) jump lead must under

no circumstances come in contact with the
positive cable connection on the starter motor.
4. Start the engine and run at high 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 starting
attempt.
Sparking hazard.
Do not lean over any of the batteries.
5. Turn off engine.

Remove the jump leads in reverse order to
installation. One lead at a time!
30
Group 23 EMS 2 Function check
Function check
check
Diagnostic function for VODIA
• The program can read off fault codes that are stored in the engine’s control unit, check input/output signals
and read off current values from the engine’s sensors and then print out the test results.
• The program allows service and workshop personnel the rapidly detect and correct faults in the
EMS 2-system.
• Connection to the engine’s control unit is via the diagnostic outlet, see chapter ”Electrical diagrams”.
• User information is included with the program.
• To order the program, contact your Volvo Penta retailer.
• The task of the diagnostic function is to discover and locate any malfunctions in the EMS 2 system, to
protect the engine and to ensure operation in the event of serious malfunction.
• If a malfunction is detected, this is indicated by the diagnostic lamp in the control panel blinking.
By pressing the diagnostic switch, the operator will receive a fault code as a guide to any fault-tracing.
For more handling information, see ”VODIA User´s Guide”.
31
Group 23 EMS 2 Fault tracing
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 the safety instructions for handling and service in the chapter ”Safetyinformation” before
starting work.
Symptoms and possible causes

The diagnostic indicator is blinking Please refer to the “Diagnostic information” chapter
Engine can not be stopped. 2, 5
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
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
23
1. Flat batteries 11.. Water/contamination in fuel

11 20.. Defective thermostat
20
2. Poor contact/open circuit in 12.. Faulty unit injector
12 21.. Blocked intercooler
21
electrical cable
13.. Insufficient air supply to the
13 22.. Too high oil level
22
3. Main switch turned off engine:
23.. Alternator drive belt slips
23
–clogged air filter
4. Main circuit breaker faulty
–air leakage between the turbo 24.. Water entry into engine
24
5. Faulty ignition lock and the engine’s inlet pipe 25.. High back pressure in the
25
6. Faulty main relay –dirty compressor part exhaust system
in the turbocharger
7. Faulty starter motor/solenoid –faulty turbocharger 26.. Break in “ Pot+ ” cable to
26
–poor engine room ventilation pedal
8. No fuel:
– fuel cocks closed 14.. Excessive coolant temperature
14
– fuel tank empty/wrong tank
connected 15.. Too low coolant temperature
15
16.. Too low oil level
16
9. Blocked secondary fuel filter/-
primary filter (because of 17.. Coolant level too low
17
contam ination, or stratification
18.. Air in the coolant system
18
of the fuel at low temperature)
19.. Faulty circulation pump
19
10.. Air in the fuel system
10
32
Group 23 EMS 2 Diagnostic function
Diagnostic function
The diagnostic function monitors and checks that the EMS 2 system functions normally.
The diagnostic function has the following tasks:
• Detecting and locating disturbances
• Reporting detection of disturbances
• Providing guidance when troubleshooting
Message regarding disturbance Effect on the engine

If the diagnosis function detect a disturbance in the The engine is affected in different ways, depending on
EMS 2 system, this is reported using fault codes via the seriousness of the fault detected by the diagnostic
the instruments. Depending on which equipment is function.
used, this is reported in various ways (fault codes can
A fault message in the form of a fault code is always
also be read using VODIA):
generated when the diagnostic function discovers a
For DCU - Display Control unit: fault.
• the text” !! ENGINE WARNING !!” shows on the The engine is affected by different degrees (see be-
display. NOTE: you can select the language with low) depending on the seriousness of the fault:
which the DCU will present the information.
• The engine is not affected.
For CIU - Control Interface Unit:
• Engine goes to idle speed (VE engines).
• the diagnostic lamp starts to flash
• Engine torque is limited to different levels (VE en-
gine)
Simultaneously, the fault will be stored in the control • Engine is shut off.
module memory. As soon as the fault has been at-
tended to and the ignition is turned off and on, the
fault code will no longer show as active.
• DCU - the fault code shows as passive
• CIU - the diagnosis lamp turns off
Both rectified (passive) and un-rectified (active) faults
are stored in the control unit.
For reading fault codes, see chapter Operation on
page 34.
All fault codes are found in the fault code list with in-
formation about cause, reaction and actions, see
chapter on ”Fault codes.”
NOTE: The indicated flashing codes apply only if the
Volvo Penta CIU is used.
33
Operation Reading fault codes via Display Control

When a disturbance has occurred and the diagnosis unit (DCU)
system has generated one or more fault codes, these When a fault code has been set, the text ”!! ENGINE
can be read either via: WARNING !!” is shown alternating with ”Press SEL for
- Plain text on instrument panel (DCU - Display information”.
Control unit). NOTE: you can select the language with which the
DCU will present the information.
- Diagnosis lamp on instrument panel (CIU - Control
Interface Unit). By pressing the button SEL, you move to the fault
- The VODIA-tool. For handling, see ”VODIA User´s list. The fault list shows:
Guide” - Running hours
If the system indicates that a fault code has been set: - Fault
1. Reduce engine speed to idle/shut down the en- - Reason for fault
gine.
- Active/inactive
2. For DCU: read which fault code has been set via
the instrument panel, See ”Reading fault codes Press ESC to exit the fault list.
via Display Control unit (DCU).” To access the fault list when no fault code has been
or set, press the button SEL to select the menu option
Diagnostics.
For CIU: press in the diagnosis button and read
the fault code via codes flashed by the diagnosis Erasing fault codes (DCU)
lamp, see ”Reading fault codes via diagnosis lamp
on instrument panel (CIU)”. Fault codes cannot be erased using DCU, but must be
erased using VODIA.
3. Look up the fault code in the fault code list and
take the necessary measures.
34
Reading fault codes via the diagnosis

lamp on instrument panel (CIU)
If the diagnosis knob is depressed and then released,
a fault code will flash.
The fault code consists of two groups of flashes, sep-
arated by a pause of two seconds. A fault code is ob-
tained by counting the number of flashes in each
group.
Example::
Example pause = Fault code 2.4
The fault code is stored and can be read as long as
the malfunction remains. You can find information
about cause, reaction and actions in the fault code
list.
Read as follows:
1. Press the diagnostic button.
2. Release the diagnostic button and make a note of
the
he fau
fault tha
ha s f ashed ou
3 Repea ems 1-2 A new fau code s f ashed ou
f more are s ored Repea un he f rs fau code
s repea ed
NOTE When he f rs fau code re urns a fau co-

des have been read
Erasing fault codes (CIU)

The d agnos s func on fau code memory s se o
zero when he vo age o he eng ne s d sconnec ed
NOTE Vo age mus be fu y d sconnec ed
When vo age s urned on aga n he d agnos s func-

on w check f here are any d s urbances n he
EMS 2 sys em If h s s he case new fau codes
are se
Th s means ha
1 Fau codes for ma func ons ha have been rec -
f ed or d sappeared are se as nac ve ( he nac-
ve fau code can hen be erased w h he VODIA
oo )
2 Fau codes for ma func ons wh ch have no been
a ended o mus be acknow edged every me he
sys em vo age s sw ched on
If he d agnos s knob s depressed af er he fau s
have been correc ed and s ored fau codes have
been de e ed code 1 1 (”No fau ”) w f ash see
chap er on ”Fau codes”
35
Group 23 EMS 2 D agnos c func on
Fault codes EMS 2

WARNING! Read he safe y ns ruc ons for hand ng and serv ce n chap er ”Safe y nforma on” before s ar-
ng work
NOTE Read ng he fau codes be ow such as PID 97 Code 2 1 means ha PID 97 s read us ng he d agnos c
oo VODIA 2 1 s he f ash ng code ha s d sp ayed by he ns rumen box d agnos s amp See ”Read ng fau
codes”
NOTE When here s a reference o socke s n he cab e harness g oves o he eng ne con ro modu e see w r ng
d agram EMS 2
Code 1 1 Nofau
No fau s PID 111 Code 2 3 Coo an eve sensor
No ac ve fau s ex s Reason
• Shor ed o p us (+)
PID 97 Code 2 1 Wa er n fue • Sensor fau y

Reac on
Reason
• None
• Wa er n fue
Remedy
Reac on
• Check ha he cab e harness o coo an eve sen-
• Warn ng nd ca or sor has no been damaged
Remedy
• Check coo an eve sensor func on
• Dra n fue pre-f er
• Check con ac pressure n socke 23 and 10 n
PID 111 Code 2 2 Coo an eve he upper cab e g ove (A) o he eng ne con ro
modu e
Reason
SID21 Code 2 4 Speed sensor f ywhee
• Low coo an eve
Reac on Reason
Warn ng nd ca or • No s gna
•
VE eng nes The eng ne con ro modu e m s en- • Abnorma frequency
•
g ne ou pu (un ess pro ec on has been urned off • ”In erm en ” s gna from he sensor
w h he d agnos s oo VODIA)
• Sensor fau y
GE eng nes The eng ne s shu down (un ess pro-
Reac on
ec on has been urned off w h he d agnos s oo
VODIA) • The eng ne s very hard o s ar and runs uneven y
f s ar s
Remedy
Remedy
• Check coo an eve
• Check ha he sensor con ac has been ns a ed
• Check he coo an empera ure sensor func on
correc y
• Check ha he cab e harness o he speed sensor
has no been damaged
• Check ha he speed sensor was ns a ed cor-
rec y n he f ywhee cas ng
• Check speed sensor func on
he upper cab e g ove (A) o he eng ne con ro
modu e
36
SID22 Code 2 5 Speed sensor camshaf whee PPID 132 Code 2 8 RPM-po en ome er
connec ed o CIU
Cause
Reason
• No s gna
• Shor ed o p us (+) or m nus (-)
• Abnorma frequency
• Po en ome er fau y
• Sensor fau y Reac on
Reac on
• VE eng nes Eng ne goes o d e
• The eng ne akes onger han norma o s ar En-
g ne runs norma y when s runn ng If you re ease he acce era or f rs and he press
down aga n he eng ne can be forced o run us-
Remedy ng he d e con ac
• Check ha he speed sensor con ac has been n- GE eng nes Eng ne speed s ma n a ned
s a ed correc y
Remedy
• Check ha he cab e harness o he speed sensor
has no been damaged • Check ha he po en ome er has been connec ed
correc y
• Check ha he speed sensor was ns a ed cor-
rec y n he upper m ng gear cover • Check ha he cab e harness o he po en ome er
Check speed sensor func on has no been damaged
•
Check con ac pressure n socke 45 and 46 n • Check he po en ome er func on
•
he upper cab e g ove (A) o he eng ne con ro
modu e PID 97 Code 2 9 Ind ca or for wa er n fue
Reason
PID 190 Code 2 6 Eng ne rpm
• Shor
Reason
• Break
• Rpm oo h gh
• D a nd ca or fau y
Reac on
Reac on
• VE eng nes None
• None
• GE eng nes Eng ne s shu off (un ess he pro ec-
on has been shu off w h he parame er se ng Remedy
oo ) • Check he cab e harness o d a nd ca or w h re-
Remedy gard o shor and break
When he mo or s ops ook for he cause of h gh • Check d a nd ca or func on Change nd ca or as

•
rpm necessary
PID 100 Code 3 1 O pressure sensor

Reason
• Break
Reac on
• None
Remedy
• Check ha he cab e harness o he o pressure

sensor has no been damaged
• Check ha he o pressure sensor has been con-
nec ed correc y
• Check con ac pressure n socke 11 n he ower
cab e g ove (B) o he eng ne con ro modu e
37
PID 105 Code 3 2 Charge a r empera ure sensor PID106 102 Code 3 4 Boos pressure sensor
Reason Reason
• Shor ed o p us (+) or m nus (-) • Shor ed o p us (+) or m nus (-)
• Break • Break
Reac on Reac on
• None • The eng ne smokes more han norma when acce -
era ng or be ng oaded
Remedy
Check ha he charge a r empera ure sensor con- Remedy
•
ac has been ns a ed correc y • Check ha he charge a r pressure sensor con ac
Check ha he cab e harness o he charge a r has been ns a ed correc y
•
empera ure sensor has no been damaged • Check ha he cab e harness o he charge a r
Check ha he charge a r empera ure sensor was pressure sensor has no been damaged
•
ns a ed correc y • Check ha he charge a r pressure sensor was n-
Check he charge a r empera ure sensor func on s a ed correc y
•
Check con ac pressure n socke 47 n he upper • Check he charge a r pressure sensor func on
•
cab e g ove (A) o he eng ne con ro modu e • Check con ac pressure n socke 22 n he upper
cab e g ove (A) o he eng ne con ro modu e
PID 110 Code 3 3 Coo an empera ure sensor
Reason PID106 102 Code 3 5 Boos pressure
Reason
• Boos pressure oo h gh
• Break
Reac on
Reac on
Pre-hea ng s a so ac va ed when he eng ne s • VE eng nes The eng ne con ro modu e m s en-
• g ne ou pu (un ess pro ec on has been urned off
ho
Remedy
• Check ha he coo an empera ure sensor con- ec on has been urned off w h he d agnos s oo
ac has been ns a ed correc y VODIA)
• Check ha he cab e harness o he coo an em- Remedy
pera ure sensor has no been damaged
• Check urbocharger func on
• Check ha he coo an empera ure sensor was
ns a ed correc y • Check he charge a r pressure sensor func on
• Check he coo an empera ure sensor func on • Check amoun of fue un n ec or
PID 94 Code 3 6 Fue pressure sensor

Reason
• Break
Reac on
• None
Remedy
• Check ha fue pressure sensor con ac has been

ns a ed correc y
• Check ha he w r ng o he fue pressure sensor

has no been damaged
• Check ha fue pressure sensor was ns a ed cor-
rec y
• Check fue pressure sensor func on
38
PID175 Code 3 7 O empera ure sensor PPID 4 Code 5 2 S ar npu CIU

Reason Reason
• Shor ed o p us (+) or m nus (-) • Shor ed o m nus (-)
• Break • Ac va ed for oo ong

Reac on Reac on
• None • The eng ne canno be s ar ed
Remedy • The eng ne s ar s mmed a e y when gn on s
Check ha he cab e harness o he o empera- urned on
•
ure sensor has no been damaged Remedy
• Check ha he o empera ure sensor has been • Check ha connec ons o he gn on key have
connec ed correc y no been damaged
• Check con ac pressure n socke 31 n he upper • Check ha he cab e harness o he gn on key
cab e g ove (A) o he eng ne con ro modu e has no been damaged
PID 94 Code 3 8 Fue pressure PPID 6 Code 5 3 S op npu CIU

Reason Reason
• Low feed pressure • Shor ed o m nus (-)
Reac on • Break
• Warn ng nd ca or • Ac va ed for oo ong
Remedy Reac on
• Check f s poss b e o ncrease pressure us ng The eng ne can on y be s opped w h he aux ary
•
he hand pump s op (AUX STOP) on he eng ne
• Check fue f er Eng ne s ops A fau code s d sp ayed for 40
•
• Check fue pre-f er seconds and he eng ne can no be s ar ed dur ng
h s me When a fau code s ac ve he eng ne
PID 158 Code 3 9 Ba ery vo age can be s ar ed bu no s opped
Reason Remedy
• A erna or fau y • Check ha connec ons o he gn on key have
no been damaged
• Ba ery ba ery cab es fau y
Reac on • Check ha he cab e harness o he gn on key
has no been damaged
• Warn ng nd ca or
Remedy PID 45 Code 5 4 Pre-hea ng re ay
Check feed vo age from he con ro modu e Reason

•
PPID 5 Code 5 1 Ma n re ay
• Break
Reason
Reac on
• Shor ed o p us (+) Pre-hea ng canno be ac va ed
•
Reac on
• Pre-hea ng s cons an y connec ed
• The ns rumen pane s d sconnec ed from power
Remedy
when he key s urned o s ar pos on Eng ne
can no be s ar ed • Check ha he cab e harness o he re ay npu
Remedy has no been damaged
• Check re ay func on
• Check ha he cab e harness o he re ay has no
been damaged • Check con ac pressure n socke 25 n he ower
• Check re ay func on
39
PID 107 Code 5 5 Pressure drop a r f er PID 98 Code 5 9 O eve sensor

Reason Reason
• B ocked a r f er • Shor ed o p us (+) or m nus (-)

Reac on • Break
• Warn ng nd ca or Reac on
Remedy • None
• Check he a r f er Remedy
• Check ha he cab e harness o he o eve sen-

PID 107 Code 5 6 A r f er sensor
sor has no been damaged
Reason
• Check he o eve sensor func on
• Check con ac pressure n socke 3 and 4 n he
• Break ower cab e g ove (B) o he eng ne con ro mod-
Reac on ue
• None PID 110 Code 6 1 Coo an empera ure

Remedy Reason
• Check ha he a r f er sensor con ac has been • Coo an empera ure oo h gh
ns a ed correc y
Reac on
• Check ha he cab e harness o a r f er sensor
has no been damaged • Warn ng nd ca or
Check ha he a r f er sensor was ns a ed cor- • VE eng nes The eng ne con ro modu e m s en-
•
rec y g ne ou pu (un ess pro ec on has been urned off
• Check he a r f er sensor func ona y
VODIA)
PID 98 Code 5 7 O eve Remedy
Reason Check coo an eve
•
• The o eve s oo ow • Check he charge a r coo er (c ean ness)
Reac on • Check for a r n he coo an sys em
• Warn ng nd ca or • Check he pressure cap on he expans on ank

Remedy • Check he coo an empera ure sensor func on
Check he o eve • Check he hermos a func on PID 98 Code 5 9
•
O eve sensor
PID 175 Code 5 8 O empera ure
Reason
• The o empera ure s oo h gh

Reac on
• VE eng nes The eng ne con ro modu e m s en-
g ne ou pu (un ess pro ec on has been urned off
VODIA)
Remedy
• Check he o eve
• Check he o empera ure
• Check he o empera ure sensor func on
40
PID 105 Code 6 2 Charge a r empera ure SID 231 Code 6 5 Da a nk (CAN) EMS 2
Reason Reason
• Charge a r empera ure oo h gh • In erna fau n he con ro modu e

Reac on Reac on
• VE eng nes The eng ne con ro modu e m s en- • Eng ne no opera ng eng ne can no be s ar ed
g ne ou pu (un ess pro ec on has been urned off Eng ne runn ng eng ne d es and can on y be
w h he d agnos s oo VODIA) s opped w h he emergency s op
GE eng nes The eng ne s shu down (un ess pro- Remedy
• Check ha he 8-p n con ac has no been dam-
VODIA)
aged
Remedy Check ha he cab e harness be ween CIU and
•
Check he charge a r coo er (c ean ness) he eng ne con ro modu e has no been damaged
•
• Check he charge a r empera ure sensor func on • Check ha socke 11 and 12 n con ac s on CIU
have no been damaged
PPID 3 Code 6 3 S ar ou pu EMS 2 Check con ac pressure n socke 51 and 55 n
•
Reason he ower cab e g ove (B) o he eng ne con ro
modu e
PID 100 Code 6 6 O pressure
• Ac va ed for oo ong
Reac on Reason
• The eng ne canno be s ar ed • The o pressure s oo ow

• The eng ne s ar s mmed a e y when gn on s Reac on
urned on Warn ng nd ca or
•
Remedy VE eng nes The eng ne con ro modu e m s en-
•
• Check ha connec ons o he gn on key have g ne ou pu (un ess pro ec on has been urned off
no been damaged w h he d agnos s oo VODIA)
• Check ha he cab e harness o he gn on key GE eng nes The eng ne s shu down (un ess pro-
has no been damaged ec on has been urned off w h he d agnos s oo
VODIA)
SID 231 Code 6 4 Da a nk (CAN) CIU
Remedy
Reason
• Check he o eve
• Da a nk fau y (CAN) CIU
• Check ha o f ers are no b ocked
Reac on
• Check sys em pressure va ves and he safe y
• Ins rumen and warn ng amps no onger work va ve n o sys em
Remedy • Check he o pressure sensor func on
• Check ha he 8-p n con ac has no been dam- • Check con ac pressure n socke 51 and 55 n
aged he ower cab e g ove (B) o he eng ne con ro
modu e
• Check ha he cab e harness be ween CIU and
he eng ne con ro modu e has no been damaged
• Check ha socke 11 and 12 n con ac s on CIU
he ower cab e g ove (B) o he eng ne con ro
modu e
41
PPID 8 Code 6 7 P s on coo ng pressure PID 158 Code 6 9 Ba ery vo age CIU
Reason Reason
• P s on coo ng pressure s oo ow • Shor ed o m nus (-)

Reac on • Fau y a erna or
• Eng ne s opped app es o bo h GE and VE en- • Ba ery ba ery cab es fau y
g nes The fau code s de-ac va ed a eng ne
Reac on
speeds be ow 1000 rpm
Remedy
Check ha he o pressure n he eng ne exceeds • Prob em when s ar ng mo or
•
175 kPa (25 4 ps ) Remedy
• Check feed vo age from he con ro modu e

PPID 8 Code 6 8 P s on coo ng pressure sensor
• Check he ba ery
Reason
• Check a erna or
• Break SID 1 Code 7 1 Un n ec or cy nder #1

Reac on Reason
• None • E ec r c fau
Remedy • Compress on or un n ec or fau y
• Check ha he p s on coo ng pressure sensor Reac on
con ac has been ns a ed correc y
• The eng ne runs on 5 cy nders
• Check ha he cab e harness o he p s on coo ng
pressure sensor has no been damaged • Abnorma sound
Check ha he p s on coo ng pressure sensor • De er ora ng performance

•
was ns a ed correc y • Cy nder ba anc ng n errup ed -> Uneven opera on
Check he p s on coo ng pressure sensor func- a ow rpms and ow oad
•
ona y Remedy
• Check con ac pressure n socke 24 n he upper
he ower cab e g ove (B) o he eng ne con ro
modu e
• Check ha he cab e harness o he un n ec ors
has no been damaged
• Check ha connec ons o he un n ec or have
no been damaged
• Check fue feed pressure
• Check he va ve c earance
• Run a compress on es and check
cy nder #1
• Check ha he cab e harness o he un n ec ors
has no been damaged
• Check ha connec ons o he un n ec or have
no been damaged
• Check fue feed pressure
• Check he va ve c earance
• Run a compress on es and check
cy nder #1
42
SID 2 Code 7 2 Un n ec or cy nder 2# SID 4 Code 7 4 Un n ec or cy nder 4#

Reason Reason
• E ec r c fau • E ec r c fau
• Compress on or un n ec or fau y • Compress on or un n ec or fau y

Reac on Reac on
• The eng ne runs on 5 cy nders • The eng ne runs on 5 cy nders
• Abnorma sound • Abnorma sound
• De er ora ng performance • De er ora ng performance
• Cy nder ba anc ng n errup ed -> Uneven opera on • Cy nder ba anc ng n errup ed -> Uneven opera on
a ow rpms and ow oad a ow rpms and ow oad
Remedy Remedy
• Check con ac pressure n socke 16 n he upper • Check con ac pressure n socke 56 n he upper
cab e g ove (A) o he eng ne con ro modu e cab e g ove (A) o he eng ne con ro modu e
• Check ha he cab e harness o he un n ec ors • Check ha he cab e harness o he un n ec ors

has no been damaged has no been damaged
• Check ha connec ons o he un n ec or have • Check ha connec ons o he un n ec or have
no been damaged no been damaged
• Check fue feed pressure • Check fue feed pressure
• Check he va ve c earance • Check he va ve c earance
• Run a compress on es and check • Run a compress on es and check
cy nder #2 cy nder #4
SID 3 Code 7 3 Un n ec or cy nder 3# SID 5 Code 7 5 Un n ec or cy nder 5#

Reason Reason
• E ec r c fau • E ec r c fau
• Compress on or un n ec or fau y • Compress on or un n ec or fau y

Reac on Reac on
• The eng ne runs on 5 cy nders • The eng ne runs on 5 cy nders

• Abnorma sound • Abnorma sound
• De er ora ng performance • De er ora ng performance
• Cy nder ba anc ng n errup ed -> Uneven opera on • Cy nder ba anc ng n errup ed -> Uneven opera on
a ow rpms and ow oad a ow rpms and ow oad
Remedy Remedy
• Check con ac pressure n socke 32 n he upper • Check con ac pressure n socke 48 n he upper
cab e g ove (A) o he eng ne con ro modu e cab e g ove (A) o he eng ne con ro modu e
• Check ha he cab e harness o he un n ec ors • Check ha he cab e harness o he un n ec ors
has no been damaged has no been damaged
• Check ha connec ons o he un n ec or have • Check ha connec ons o he un n ec or have
no been damaged no been damaged
• Check fue feed pressure • Check fue feed pressure

• Check he va ve c earance • Check he va ve c earance
• Run a compress on es and check • Run a compress on es and check
cy nder #3 cy nder #5
43
SID 6 Code 7 6 Un n ec or cy nder 6# PID 153 Code 7 8 Crankcase ven a on pressure

sensor
Reason
Reason
• E ec r c fau
• Compress on or un n ec or fau y
Reac on • Break
Reac on
• The eng ne runs on 5 cy nders
Abnorma sound • None
•
Remedy
• De er ora ng performance
• Check ha he crankcase ven a on pressure
• Cy nder ba anc ng n errup ed -> Uneven opera on sensor con ac has been ns a ed correc y
a ow rpms and ow oad
• Check ha he cab e harness o he crankcase
Remedy ven a on pressure sensor has no been dam-
Check con ac pressure n socke 40 n he upper aged
•
cab e g ove (A) o he eng ne con ro modu e Check ha he crankcase ven a on pressure
•
Check ha he cab e harness o he un n ec ors sensor was ns a ed correc y
•
has no been damaged • Check crankcase ven a on pressure sensor
Check ha connec ons o he un n ec or have func on
•
no been damaged • Check con ac pressure n socke 28 n he ower
Check fue feed pressure cab e g ove (B) o he eng ne con ro modu e
•
• Check he va ve c earance PID 172 Code 7 9 A r empera ure sensor n e
• Run a compress on es and check Reason
cy nder #6
PID 153 Code 7 7 Crankcase ven a on pressure
• Break
Reason
Reac on
• Crankcase ven a on pressure oo h gh • None
Reac on Remedy
• Warn ng nd ca or Check ha he a r empera ure sensor con ac has
•
• The eng ne s shu down been ns a ed correc y
Remedy • Check ha he cab e harness o he a r empera-
ure sensor has no been damaged
• Check whe her he crankcase ven a on s
c ogged • Check ha he a r empera ure sensor was n-
s a ed correc y
• Check whe her cy nder ner p s on or p s on r ngs
are worn or damaged • Check he a r empera ure sensor func ona y
44
SID250 Code 9 2 Da a nk fau y (J1708 J1587) SID 254 Code 9 8 Con ro modu e fau CIU
Reason Reason
• Da a nk fau y • EEPROM CIU fau y

Reac on • F ash memory CIU fau y
• Warn ng nd ca or • Fau n con ro modu e CIU
Remedy Reac on
• Check ha he 8-p n con ac has no been dam- • CIU rever s o fac ory se ngs
aged
• The eng ne runs o d e
• Check ha he cab e harness be ween CIU DCU
and he eng ne con ro modu e has no been dam- • Eng ne canno be s ar ed
aged Remedy
• Check ha socke 22 and 37 n con ac s on CIU • Rep ace CIU-un
Check con ac pressure n socke 33 and 34 n SID 240 Code 9 9 Memory fau n EMS
•
he upper cab e g ove (A) o he eng ne con ro Reason
modu e
• Eng ne con ro modu e memory fau
SID232 Code 9 3 Vo age feed o sensor Reac on
Reason
• Eng ne may no s ar
• Shor Remedy
• Fau n o pressure and or charge a r pressure • Rep ace he eng ne con ro modu e
sensor
Reac on SID 253 Code 9 9 Da a se memory EEPROM
Incorrec va ues from o pressure- and charge a r Reason

•
pressure sensor • In erna fau n he con ro modu e
• Fau code for o pressure- and charge a r pres- • Programm ng fau y
sure sensor
Reac on
• Low eng ne ou pu
• Eng ne does no s ar
• The ns rumen shows zero o pressure and boos
Remedy
pressure
• Reprogram he con ro modu e If he fau re-
Remedy
ma ns change he con ro modu e
• Check ha he cab e harness o o pressure- and
charge a r pressure sensor has no been dam- SID 254 Code 9 9 Con ro modu e EMS
aged Reason
• In erna fau n he con ro modu e
Reac on
• Check o pressure and charge a r pressure sen-
sors • Eng ne m sf res
• Eng ne does no s ar
Remedy
• Rep ace he eng ne con ro modu e
45
Group 23 EMS 2 E ec r ca fau rac ng
Electrical fault tracing

General Functional check of wiring and
Before perform ng e ec r ca fau rac ng he connector blocks
fo ow ng shou d be checked
• Fau codes
Connection problems
• Fue eve and f er
Loose connec ors or occas ona y recurr ng fau s can
• A r f er
be d ff cu o fau race and of en occur due o ox da-
• Ba ery on v bra on or poor y connec ed eads
• Cab e harness (v sua y) Wear can be ano her reason for fau s Therefore
• Ma n sw ch fuses connec or b ock avo d d sconnec ng connec or b ocks f s no nec-
essary
• Connec ons o re ay
O her connec or prob ems can ar se due o p ns sock-
e s and connec or b ocks be ng damaged
Shake he ead and pu on he connec or wh e mea-
sur ng o he p f nd damaged w r ng
The res s ance n connec ors w r ng and connec ons
shou d be 0 Ohm
A cer a n res s ance s a ways presen however due
o ox da on of connec ons
If h s res s ance ncreases oo much can ead o
ma func ons The s ze of he res s ance before
s ar s caus ng ma func ons var es depend ng on how
arge a oad he c rcu s carry ng
Check he fo ow ng
• Look for ox da on ha can worsen
connec or con ac n he connec ons
• Check ha he connec or p ns socke s are un-

damaged ha hey are proper y nser ed n he
connec or b ocks and ha he w res are proper y
connec ed o he p ns
• Tes he connec or b ocks for good mechan ca

con ac
Use a oose p n for he es
Impor an ! The con ro un ’s (EMS 2) cab e

connec or mus on y be checked w h gauge
9998482
• Push gauge 9998482 carefu y n o he connec or

socke s Pu push he gauge back and for h sev-
era mes check ha he socke gr ps around he
gauge If he connec or socke has nsuff c en
gr pp ng power he socke mus be rep aced See
”Sp c ng cab es for cab e connec ors”
• F connec or socke s ha have been checked

w h ow empera ure grease 1161417-9
Impor an ! DIN connec ors for he pressure
sensor mus no be f ed w h grease
• Check ha he w res are proper y cr mped Avo d

shor cr mps on w res o he connec or p ns socke s
46
Functional check of wiring and

connector blocks
Check connections visually Connector resistance and oxidation
Check he fo ow ng The res s ance n connec ors w r ng and connec ons
shou d be 0 Ω
• Look for ox da on ha can worsen connec or con-
ac n he connec ons A cer a n res s ance s a ways presen however due
o ox da on of connec ons
damaged ha hey are proper y nser ed n he If h s res s ance ncreases oo much can ead o
connec or b ocks and ha he w res are proper y ma func ons The s ze of he res s ance before
connec ed o he p ns s ar s caus ng ma func ons var es depend ng on how
arge a oad he c rcu s carry ng
• Tes he connec or b ocks for good mechan ca
con ac Check he fo ow ng
Use a oose p n for he es • Look for ox da on ha can worsen connec or con-
ac n he connec ons
• Shake he ead and pu on he connec or wh e
measur ng o he p f nd damaged w r ng
damaged ha hey are proper y nser ed n he
connec or b ocks and ha he w res are proper y
connec ed o he p ns
Open circuit
Chafed or orn w r ng as we as oose con ac s can be • Tes he connec or b ocks for good mechan ca
con ac
poss b e fau causes
Use a oose p n for he es
Check us ng he w r ng d agram wh ch cab e harness
s used by he func on S ar w h he mos ke y ca- Impor an ! DIN connec ors for he pressure
b e harness n he c rcu sensor mus no be f ed w h grease
Check he fo ow ng
• D sconnec he connec or b ocks a bo h ends of
he cab e harness
• Measure he res s ance w h mu me er 9510060

be ween he ends of he cab e Expec ed va ue
~0Ω
• Shake he ead and pu on he connec or wh e

measur ng o he p f nd damaged w r ng
• If he fau canno be found check he nex cab e

harness accord ng o he w r ng d agram
47
Splicing cables for cable

connectors
Spec a oo s 951 2636 9999324
Repa r k 1078054
1 D sconnec he connec or b ock from he con ro

un see ”Con ro un rep ace” D sman e he
connec or b ock so ha he p n socke o be re-
p aced s access b e
2 Remove he p n socke w h oo 9992636 or w h a
very sma ewe ers screwdr ver
NOTE On y remove one p n a a me
3 Cu off he w re w h he p n ha s o be rep aced

Sp ce n he new par from repa r k 1078054
Use cr mp ng oo 9999324
4 Carefu y hea he sp ce w h a ho a r gun so ha
he nsu a on shr nks around he w re
5 Rep ace he p n n he correc pos on n he con-
nec or b ock before remov ng he nex p n f sev-
era p ns are o be rep aced Check ha he ock-
ng ab engages and ocks he p n n he connec or
b ock
6 Reassemb e he w r ng w h nsu a on and cab e
es n he connec or b ock n he reverse order o
d sman ng
7 Reassemb e he connec or b ock n he reverse or-
der o d sman ng
8 Ensure ha he cab e connec or and connec or on
he con ro un are c ean and dry
9 F he cab e connec or b ock on o he con ro un
see “Con ro un rep acemen ”
10 S ar he eng ne and check for error codes
48
Check of combination sensor,

Check sensor, Check of sensor,
Check sensor, coolant
charge air pressure/charge air temperature
temperature
Check charge air pressure

1 Turn off eng ne 1 Turn off eng ne
2 D sconnec connec or A on he con ro un and 2 Remove he con ac and remove he sensor from
connec he 62-p n adap er 9998699 be ween he he eng ne
con ro un and cab e harness Then connec mu - 3 Measure us ng mu me er 9510060-8 be ween he
me er 9510060 be ween measuremen po n s sensor’s wo con ac p ns The mu me er shou d
7–11 d sp ay a va ue as shown n he ad acen d agram
3 Turn on he con ro vo age and graph c
4 Measure w h he mu me er se o vo age mea-
suremen Check ha he mu me er shows 5 0 NOTE The sensor s very sens ve o empera ure
vo changes When measur ng n he ower empera ure
5 Now connec he mu me er be ween measure- ranges 0-40°C (32-104°F) s suff c en o ho d he
men po n s 11–22 The vo age shou d be approx sensor n your hand for he res s ance va ue o drop
1 2 V a norma a mospher c pressure rap d y
Check charge air temperature

1 De ach he connec or o he charge pressure sen-
sor
2 D sconnec connec or A on he con ro un and
connec he 62-p n adap er 9998699 o he cab e
harness w h he con ro un d sconnec ed
3 Measure w h mu me er 9510060 se o res s-
ance measuremen be ween he adap er’s mea-
suremen po n s 11 –47
The mu me er shou d show he fo ow ng va ues
~15800 Ω -20 °C (-4 °F)
~2500 Ω 20 °C (68 °F)
~850 Ω 50 °C (122 °F)
NOTE Even f he res s ance va ues n he ab e abo-

ve are me h s s no guaran ee ha he sensor s no
fau y
49
Checkk of sensor,
Chec sensor, water in fuel
Tempera ure Res s ance
-20 °C (-4 °F) 15462 Ω
1
-10 °C (14 °F) 9397 Ω
0 °C (32 °F) 5896 Ω
10 °C (50 °F) 3792 Ω
20 °C (68 °F) 2500 Ω
23 °C (73 °F) 2057 Ω
30 °C (86 °F) 1707 Ω
40 °C (104 °F) 1175 Ω
50 °C (122 °F) 834 Ω
60 °C (140 °F) 596 Ω
70 °C (158 °F) 435 Ω
80 °C (176 °F) 323 Ω
Coo an empera ure 1 D sconnec he connec or (1) o he wa er n fue

sensor
2 Measure w h mu me er 9510060 se o res s-
ance be ween he p ns of he connec or o he
sensor
3 The mu me er shou d show
- open c rcu when he sensor s mmersed n fue
- shor c rcu when he sensor s mmersed n wa er
50
Check of sensors, camshaft Checking

Checking sensor,
sensor, oil pressure
and flywheel
Check of oil pressure function

The speed sensors for he camshaf and f ywhee are
den ca For v sua check ng f rs remove he sensor 1 Turn off eng ne
from he eng ne Then remove he connec on b ock 2 D sconnec he o pressure sensor connec or
and check ha he sensor s no damaged and ha no b ock and connec he 4-p n adap er 9998534 be-
swarf f ngs have s uck o he sensor ween he o pressure sensor’s connec or un and
The nduc on es s performed as fo ows he eng ne cab e harness Then connec he mu -
me er 9510060 be ween measuremen po n s 1–4
1 Se mu me er 9510060 o res s ance measure-
men Measure w h he mu me er on he connec- 3 Turn on he con ro vo age
on p ns The res s ance shou d be w h n 4 Measure w h he mu me er se o vo age mea-
775–945 Ω suremen Check ha he mu me er shows 5 0
2 Pass a me a ob ec qu ck y and c ose y by he vo
sensor Check ha he mu me er reac s When 5 Now connec he mu me er be ween measure-
rep ac ng and ns a ng sensor make sure ha men po n s 2-4 Vo age shou d be abou 0 5 V a
any spac ng sh ms are ref ed norma a mospher c pressure
51
Check of sensor,
Check sensor, Checking combined sensor,
Checking sensor,
coolant level oil level/oil temperature
1 Emp y he expans on ank from coo an Check of oil level function

1 Remove connec or b ock from he o eve sensor
WARNING! NEVER open he expans on ank
pressure cap when he eng ne s ho ho coo an 2 Measure us ng mu me er 9510060 be ween he
can be sprayed ou and cause severe burns sensor con ac p ns 1–2
The mu me er shou d show 11 7 - 12 9 Ω
2 Re ease he connec or b ock from he coo an a 22° C (72° F)
eve sensor
3 Check ha he sw ch s ac va ed and ha
sends a s gna when he expans on ank s Check of oil temperature function
emp y 1 Remove he connec or o he o empera ure sen-
4 Then f he expans on ank w h coo an sor
and check ha he res s ance s nf n e 2 Connec he 4-p n adap er 9998534 be ween
he o pressure sensor connec or and eng ne har-
ness
3 Measure w h mu me er 9510060 ad us ed o
measure res s ance be ween he adap er mea-
suremen po n s 3–4
The mu me er shou d show he fo ow ng va ues
1520 Ω ± 126 Ω 25° C (77° F)
378 Ω ± 23 Ω 60 °C (140 °F)
104 Ω ± 4 Ω 100 °C (212 °F)
fau y
52
Check
Check of sensor,
sensor, fuel pressure Check of sensor,
Check sensor, crankcase
pressure
1 Turn off eng ne 1 Turn off eng ne

2 D sconnec he o pressure sensor connec or 2 D sconnec he charge a r pressure sensor con-
b ock and connec he 7-p n adap er 9998567 be- nec or b ock and connec he 4-p n adap er
ween he o pressure sensor’s connec or un and 9998534 be ween he charge a r pressure sensor’s
he eng ne cab e harness Then connec he mu - connec or b ock and he eng ne cab e harness
me er 9510060 be ween measuremen po n s 1–4 Then connec he mu me er 9510060 be ween
3 Turn on he con ro vo age measuremen po n s 1–4
4 Measure w h he mu me er se o vo age mea- 3 Turn on he con ro vo age

suremen Check ha he mu me er shows 5 0 4 Measure w h he mu me er se o vo age mea-
vo suremen Check ha he mu me er shows 5 0
5 Now connec he mu me er be ween measure- vo
men po n s 2 – 4 Vo age shou d be abou 0 5 V 5 Then connec he mu me er be ween measure-
a norma a mospher c pressure men po n s 2 –4 Vo age shou d be abou 3 V a
norma a mospher c pressure
53
Checking combined sensor,

Checking sensor,
air filter pressure/air
temperature
Checking air filter pressure function

1 Remove he connec or from he sensor
2 Connec he 4-p n adap er 9998534 be ween
ness
suremen po n s 1–2 The mu me er shou d show
330 Ω If he measured he va ue s 2 2 kΩkΩ when
he eng ne s shu -down h s means ha he con-
ac s s uck n ac ve pos on
Checking air temperature function

1 De ach he connec or o he o pressure sensor
2 Connec he 4-p n adap er 9998534 be ween
ness
suremen po n s 3–4 The mu me er shou d show
he fo ow ng va ues
16445 Ω ±822 Ω 0 °C (32 °F)
5000 Ω ±220 Ω 25° C (77° F)
4026 Ω ± 160 Ω 30° C (86° F)
1246 Ω ±40 Ω 60 °C (140 °F)
463 Ω ±10 Ω 90 °C (194 °F)

fau y
54
Fault tracing unit injectors Fault tracing starter motor and

cabling
Genera
If he vo age eve measured across he ba ery s
ess han 24 7V he s ar er mo or w no be ab e o
crank he eng ne a norma speed
Voltage measurement check

1 Check ha he vo age across he ba ery s a
eas 24 7V un oaded by measur ng across he
ba ery erm na s w h mu me er 9510060
2 Turn on he ma n c rcu breaker
3 check ha he vo age be ween erm na s 30 and
31 on he s ar er mo or s he same as he ba -
ery’s
Brushes
The spec f ca on for he s ar er mo or brushes
s g ven be ow
Brush cond on
New = 23 mm (0 91")
Rep ace a = 13 mm (0 51")
Fault symptom
Eng ne runs uneven y or has reduce performance
Cause
The fau symp om above can have severa
causes
• Fau y sensor s gna s
• Worn p s on r ngs
• B ocked a r f er
• Poor fue
• Wa er n fue
• A r n fue
• Exhaus pressure oo h gh
• B ocked fue sys em

• Low fue pressure
• Incorrec va ve c earances
• Defec ve un n ec or
• S ar of p s on se zure (eng ne fa ure)
55
Functional check of relay

Mu me er 9510060 s used dur ng he fau rac ng
procedure
Two d fferen symbo s v sua ze conduc or s a us
Symbo 1 nd ca es open c rcu or very h gh res s-
ance (~) The mu me er does no sound
Symbo 2 nd ca es connec on or very ow res s ance
The mu me er sounds
Perform a func ona check of he re ay as fo ows
NOTE Remove he ma n re ay from he eng ne before

fau rac ng
1 Use he mu me er se o buzzer s gna Measure

be ween re ay p ns 87a and 30 The mu me er
shou d sound
2 Use he mu me er se o buzzer s gna Measure
be ween re ay p ns 87a and 30 The mu me er
shou d sound
3 Use he mu me er se o res s ance measure-
men Measure be ween re ay p ns 85 and 86 The
mu me er shou d show 240–270 Ω
4 Connec 24V be ween p ns 85 and 86 Use he
mu me er se o buzzer s gna Measure be ween
re ay p ns 87 and 30 The mu me er shou d
sound
5 Connec 24V be ween p ns 85 and 86 Use he
mu me er se o buzzer s gna Measure be ween
re ay p ns 87a and 30 The mu me er shou d no
sound
6 Rep ace he re ay f he above es s no comp e -
ed sa sfac or y
56
Group 23 EMS 2 E ec r ca sys em
Electrical system
Important information -
electrical system
Impor an ! Turn he eng ne off and urn off he
power a he ma n sw ch(es) before carry ng ou
work on he e ec r ca sys em
1 Ba ery ma n sw ch 3 If s ar ng w h he he p of aux ary ba er es see

Never break he c rcu be ween he a erna or and ”S ar ng w h aux ary ba er es”
he ba ery wh e he eng ne s runn ng 4 Connec ng ex ra equ pmen
The ma n sw ches mus never be d sconnec ed
before he eng ne has been s opped A ex ra equ pmen sha be connec ed o a sepa-
If he c rcu s broken wh e he eng ne s runn ng ra e connec on box and correc y fused
he vo age Ex ra power ake-off d rec y from he ns rumen
regu a or can be des royed and he a erna or bad- pane shou d be avo ded The perm ed ex ra ake
y damaged off s however o a y max 5A (app es o a n-
D s- reconnec on of he charg ng c rcu shou d s rumen pane s o
for he same reason never be performed wh e he ge her)
eng ne s runn ng For s mu aneous charg ng of
Electric welding
wo ndependen ba ery c rcu s a Vo vo Pen a
charg ng separa or can be f ed o he s andard Remove he pos ve and nega ve cab es from he
a erna or (accessory) ba er es
Then d sconnec a cab es connec ed o he a erna-
2 Ba er es or
Never m x up he ba ery’s pos ve and nega ve
erm na s when f ng ba er es Then remove he cab e connec on from he con ro
Incorrec ns a a on can resu n ser ous damage un see ns ruc ons n ”Con ro un (EMS 2) re-
o he e ec r ca equ pmen p ace”
Refer o he w r ng d agram The ba ery erm na s A ways connec he we der ground c amp o he com-
shou d be we c eaned and he erm na c amps ponen o be we ded and as c ose as poss b e o he
greased and proper y gh ened we d s e The c amp mus never be connec ed o he
Fas charg ng of he ba er es shou d be avo ded eng ne or n such a way ha curren can pass hrough
If fas charg ng mus be performed he ord nary a bear ng
ba ery cab es mus be removed f rs Impor an ! Af er we d ng s f n shed he d scon-
NOTE Fo ow he appropr a e safe y regu a ons nec ed componen s such as cab e connec ors
when charg ng ba er es a erna or cab es and ba ery cab es mus be re-
Dur ng charg ng he ce covers shou d be oosened f ed n he correc order
bu no removed Ven a e we espec a y f he ba e-
r es are charged n an enc osed space
A ways d scon nue he charg ng curren before d s-
connec ng he charg ng c ps
WARNING! Never expose he ba ery area o

naked f ame or e ec r ca sparks Never smoke
c ose o he ba er es The ba er es genera e
oxy-hydrogen gas when charged wh ch forms
an exp os ve gas when m xed w h a r Th s gas
s eas y gn ed and h gh y exp os ve
A ways use pro ec ve gogg es when charg ng and

hand ng he ba er es
Ba ery e ec ro y e con a ns su fur c ac d wh ch s
h gh y corros ve
Shou d he ba ery e ec ro y e come n o con ac w h
unpro ec ed sk n wash off mmed a e y us ng p en y of
wa er If ba ery ac d comes n con ac w h he eyes
mmed a e y f ush w h p en y of wa er and ob a n med-
ca ass s ance a once
57
Electrical system, overvie

overview
w
TAD1640-1642GE, TWD1643GE with CIU,
CIU, CAN based SAE J1939
TAD1640-1642GE, TWD1643GE with DCU,

DCU, CAN based SAE J1939
58
TAD1641-1643VE, TAD1650VE with CIU, CAN based SAE J1939
TAD1631641-1643VE, TAD1650VE with DCU, CAN based SAE J1939
59
Electrical diagram EMS2

un ess
P s on coo ng p essu e senso
Senso coo an empe a u e
Senso c ankcase p essu e
Senso cha ge a p essu e

Ma n c cu b eake 10 A
S op bu on p ess bu on
cha ge a empe a u e
Con o modu e EMS 2

Un n ec o Cy 1 6
Senso ue p essu e
Connec o no used
Cab e c oss sec on = 0 75 mm

Senso coo an eve
Senso wa e n ue
Senso o p essu e
Re ay p e hea ng
J1939 CAN bus
e nd ca o
Vo age a e key
Ba e y nega ve
ywhee
Senso camsha
Senso o eve
Ba e y 24 V
VOD A npu
Connec o A
Connec o B
S a e mo o
Ba e y p us
P e hea ng
J1587 bus
Ma n e ay
Ex a s op
LBN = L gh b own
A e na o
Aux s op
LBL = L gh b ue
Jumpe
o he w se s a ed
Senso
O R = O ange
Y = Ye ow
BN = B own
V O = Pu p e
Cab e co ors
G N = G een
W = Wh e
SB = B ack
G R = G ey
BL = B ue
P = P nk
R = Red
A
1
2
3
4
5
6
7
8
9
23
24
10
12
13
25
14
15
17
18
19
20
21
22
26
27
28
29
30
31
32
33
34
16
11
60
Wiring diagram CIU 1

2
Key sw ch unn ng powe 15+
RPM po en ome e
3 Tachome e code 14
4 O p essu e ns umen
5 O empe a u e ns umen
Cab e co ors 6 Coo an empe a u e ns umen
7 ns umen um na on
BL = B ue P = P nk 8 d e sw ch wo pos on
LBL = L gh b ue R = Red 9 1500 1800 sw ch wo pos on
BN = B own SB = B ack 10 S a sw ch sp ng e u n
LBN
LBN = L gh b own VO = Pu p e 11 S op sw ch sp ng e u n
GN = G een W = Wh e 12 D agnos s con ac sp ng e u n
GR = G ey Y = Ye ow 13 A a m ow o p essu e
OR = O ange 14 A a m h gh o empe a u e
15 A a m h gh coo an empe a u e
16 A a m ow coo an eve
17 Fue a a m
18 D agnos c amp
19 Eng ne ove speed nd ca on GE
20 Ope a on nd ca o
21 P e hea ng nd ca on
22 P e hea ng con ac
23 8 p n Deu sch connec ng p ug
24 Regu a o con ac
25 Ba e y vo age a a m
26 Te m na on es s ance 120 Ohm
27 8 p n Deu sch connec ng socke
28 Con ac eng ne p o ec o d sconnec
no connec ed on GE eng nes
29 Easy L nk connec o b ock
30 Con o n e ace Un C U
61
Wiring diagram DCU
Cab e co ors
BL = B ue
LBL = L gh b ue
BN = B own
LBN = L gh b own
GN = G een
GR = G ey
OR = O ange
P = P nk
1 S a con ac R = Red
2 S op con ac SB = B ack
3 1 p n connec o b ock VO = Pu p e
4 Ho n buzze a a m W = Wh e
5 Easy L nk connec o b ock Y = Ye ow
6 RPM po en ome e
7 nd ca o eng ne ope a on
8 8 p n Deu sch connec ng p ug Cab e c oss sec on
9 8 p n Deu sch connec ng socke = 0 75 mm un ess
10 Te m na on es s ance 120 Ohm o he w se no ed
11 D sp ay Con o un DCU
62
Notes
63
Notes
64
Reportt form
Repor form
Do you have any comp a n s or o her commen s abou h s manua

P ease make a copy of h s page wr e your commen s down and send
hem o us The address s a he bo om We wou d prefer youyou o wr e n
Eng sh or Swed sh
Fro
rom
m
Refers o pub ca on
Pub ca on No Da e of ssue
Proposa mo va on
Da e
S gned
AB Vo
Vo vo Pen a
Techn ca Informa on
Dep 42200
42 200
SE-405 08 Gö eborg
Sweden
7746032 Eng sh 10 2009

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Parsianind Library Document Name: 7746032_view  Start Reading Online  Headings  Pages - 100% +

Tools ...................................................................... 9 Electrical fault tracing ......................................... 46

Limit values ......................................................... 21

Group 23 EMS 2 Safety information

Important Never start the engine without installing the air

Group 23 EMS 2 Safety information

Group 23 EMS 2 Safety information

© 2008 AB VOLVO PENTA

Group 23 EMS 2 General

product in question will not be covered under any war-

IMPORTANT! When spare parts are needed,

Group 23 EMS 2 Repair instructions

Group 23 EMS 2 Repair instructions

Group 23 EMS 2 General

The sign above shows:

The sign above shows:

Explanation of engine designation:

Group 23 EMS 2 Tools

951 2636 999 8482 999 8534

999 8567 999 8699 999 9324

951 0060 3838619 874427

Tool Designation – use

Group 23 EMS 2 Technical data

Sensor, water in fuel

Sensor, fuel pressure

Camshaft sensor/flywheel sensor

Sensor, oil pressure

Combined sensor, oil level/oil temperature

Combination sensor, charge air pressure/charge air temperature

Group 23 EMS 2 Technical data

Sensor, coolant temperature

Sensor, coolant level

Sensor, crankcase pressure

Sensor, piston coolant pressure

Combined air filter pressure and temperature sensor

Group 23 EMS 2 Design and function

Design and function

CAN (Controller Area Network) DCU (Display Control Unit)

Group 23 EMS 2 Design and function

Input signals Output signals

Engine speed Cooling water temperature

Accelerator setting Boost air temperature

Piston cooling pressure Air temperature

Camshaft position Crankcase pressure

Coolant level Fuel pressure

Group 23 EMS 2 Design and function

Fuel control Cylinder balancing

Group 23 EMS 2 Design and function

Sensor,, water in fuel (11)

Oil pressure sensor (9)

Group 23 EMS 2 Design and function

Charge air pressure/charge air

Coolant temperature sensor (16)

Fuel pressure sensor (10)

Coolant level sensor (1)

Group 23 EMS 2 Design and function

Oil level sensor / oil temperature

Crankcase pressure sensor (13)

Piston cooling pressure sensor (17)

Air filter pressure sensor / air filter

Group 23 EMS 2 Design and function

Control module EMS 2

• charge air pressure