Installation I

EMS 2 1(1)
Industrial Engines
TAD1341GE, TAD1342GE, TAD1343GE, TAD1344GE
TAD1345GE, TAD1350GE, TAD1351GE, TAD1352GE
TAD1353GE
TAD1340VE, TAD1341VE, TAD1342VE, TAD1343VE
TAD1344VE TAD1345VE
Content
Safety Information ...................................................................................... 2
Installation Tools and Documentation ...................................................... 4
Special Tools ............................................................................................ 4
System Information .................................................................................... 5
EMS ........................................................................................................... 5
Control System Installation ..................................................................... 17
Connection ............................................................................................. 17
Parameter Setting .................................................................................. 34
Diagnostic Function ............................................................................... 40
Fault Code Register ............................................................................... 43
Alphabetical index .................................................................................... 57

1
Safety Information
Presentation
This installation manual contains information for
installing and carrying out function and performance
checks on the EMS 2 system (electronic control of the
injection system).
This instruction manual is intended only for professio-
nal use.
Read the instructions carefully before starting the
installation. If the installation is performed in an incor-
rect manner, it may cause personal injury or damage
to property and machinery.
Ask your Volvo Penta dealer for help if there is any-
thing in this manual that you do not understand or are
uncertain about.
Working methods
The work must be performed by a Volvo Penta work-
shop or other authorized, well-equipped workshop by
qualified and experienced personnel.
These instructions refer to such personnel as fitters.
This installation manual is intended to be used
together with the operator's manual for the engine
concerned. The fitter is responsible for ensuring that
the system functions in accordance with these instal-
lation instructions.
Volvo Penta disclaims all responsibility for injury to
persons or damage to property that may occur as a
result of not following the installation guidelines, or for
work carried out by unqualified personnel.

!
This symbol is used in the manual and on the product to call attention to the fact that
this is safety information. Always read such information very carefully.
Safety texts in the installation manual have the following order of priority:

DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.

WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.

CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.

IMPORTANT!
Indicates a situation which, if not avoided, could result in property damage.

NOTICE! Used to draw attention to important information that will facilitate work or
operations.

This symbol is used on our products in certain cases and it refers to important
information in the operator's manual. Make sure that warning and information symbols
on the engine are clearly visible and legible. Replace symbols that have been damaged
or painted over.

2 7748542 10-2009
 Safety Information

Set out below is a summary of the risks and safety measures that must be observed or carried out when the EVC
system is installed and calibrated.

! !
Disconnect connectors to the EMS control unit before Never expose battery compartments to open flames
any arc welding is carried out. or electrical sparks. Never smoke in the vicinity of the
Turn the current off at the main switches. batteries.
Undo and remove the control unit connectors. Batteries generate hydrogen gas during charging,
Reconnect the EMS 2 control unit connectors once which can combine with air to form an explosive mix-
welding is completed and the welding equipment has ture. This gas is highly flammable and explosive.
been removed. Incorrect connection of the batteries may cause
sparks that in turn cause an explosion resulting in
! damage.
Take care to keep clear of the engine's moving parts Do not switch battery connections when attempting to
during functional checks and operations. There is a start the engine (risk for sparks) and do not lean over
risk for personal injury when approaching a running the batteries. Refer to the instructions in the engine
engine. Remember that loose clothing and long hair operator's manual.
can fasten in rotating parts and cause serious injury.
!
! Make sure that the positive (+) and negative (-) battery
Never work on an engine that is suspended from lifting cables are correctly connected to the corresponding
gear (a crane or similar). battery terminals. Serious damage may be caused to
! the electrical equipment if the cables are transposed.
The engine must not be run in areas where there are Refer to the wiring diagram in the engine operator's
explosive materials or gases. manual.

! !
Only start the engine in well-ventilated places. If the
engine is operated in an enclosed space, make sure
that there is sufficient ventilation to remove the
exhaust gases and crankcase fumes from the work-
place.
Always wear eye protection when charging or han-
dling the batteries. Battery electrolyte contains sulfu-
ric acid which is highly corrosive. If electrolyte comes
into contact with bare skin, wash the exposed area
immediately with copious amounts of clean water and
soap. Then seek medical attention. If you get battery
electrolyte in your eyes, flush them immediately (pref-
erably using eye wash equipment) with copious
amounts of clean water. Then seek immediate medi-
cal attention.

7748542 10-2009 3
Installation Tools and Documentation, Special Tools

Installation Tools and Documentation

Special Tools

p0005125

3838619 VODIA, diagnostic 9812519 Multimeter

tool
VODIA, complete with cable har- Multimeter
ness
Refer to the VODIA operators
manual when ordering separate
parts.

Other Special Equipment

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

P0003813 P0003809

HDT-48–00 AMP 539 968 AMP 726 519

Press tool Removal tool, 1.5 mm pin width Removal tool, 0,06 inch pin width

P0003811
P0003810 P0003813

AMP 726 519 AMP 929 039 AMP 238 635

Removal tool, 2.8 mm pin width Removal tool, 2.8 mm pin width Press tool

P0003811 P0003814

AMP 825 514 GHW 50000 017 586

Press tool Removal tool, 2.8 mm pin width
For 4.8 and 6.3 cable shoes. For GHW connector (relay box)
Flat-pin connectors.

4 7748542 10-2009
 System Information, EMS

System Information

EMS
Motorstyrsystem
EMS 2 stands for “Engine Management System” and
is an electronic system with CAN communications
(Controller Area Network) for control of diesel engines.
The system has been developed by Volvo Penta and
includes fuel control and diagnosis function. The sys-
tem consists of a control module, six unit injectors, a
number of sensors that supply the control module with
measurements, sockets for diagnosis and functional
checks. The engine can be connected to a communi-
cation interface comprising a CAN-link and a serial link.

CAN (Controller Area Network)

The CAN J1939 link handles all communication
between the engine control module EMS 2 and the
CIU, in addition to the diagnostics that are handled by
the so called J1708/J1587 link. The CAN link is much
faster than the J1708/J1587 link. The CAN link has
been prepared to connect to other components with
SAE J1939 protocol such as instrument panels and
transmissions.

If, for some reason, a fault develops on the CAN link,

signals for the rpm-potentiometer and the start and
stop knobs are taken over by the J1708/J1587 link.
However, instrument and indicator lamps are com-
pletely turned off. If a fault occurs on both links, GE
engines maintain engine speed, while VE engines go
to idle. The only way to shut off the engine in this case
is to use the auxiliary stop (AUX-STOP) placed on the
engine’s left side.

7748542 10-2009 5
System Information, EMS

CIU (Control Interface Unit)

The CIU is a “translator” between the CAN bus and the
customer’s own control panel. This unit has two serial
communication links, one fast and one slow. The fast
one is a CAN link that features a bus speed of 250 Kbit/
s. All data regarding instruments, indicator lamps, con-
tacts and potentiometers are controlled by this bus.
The slower J1708/J1587 link handles diagnostic infor-
mation for, among other things, the flashing code. The
diagnosis tool VODIA also uses the J1708/J1587 link
to communicate with the system.
P0002060

6 7748542 10-2009
 System Information, EMS

Fuel control

The engine’s fuel requirement is analyzed up to 100 Altitude correction

times per second (depending on engine rpm). The
engine’s injection amount and injection timing is con-
trolled electronically via fuel valves on the unit injec-
tors.
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-
sions etc.
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
angle. The control is primarily performed using the
speed sensors and the combined sensor for boost
pressure/charge air temperature.
The control module affects the unit injectors via an
electronic signal to the unit injectors’ electromagnetic
fuel valve, which can open and close.
When the fuel valve is open, fuel flows through the
unit injector hole and out through the fuel channel.
Fuel is not sprayed into the cylinder in this position.
When the fuel valve closes, pressure starts to build
from the unit injector’s mechanically operated pump
plunger. When sufficient pressure has developed, fuel
is injected into the cylinder via the unit injector’s injec-
tor section.
The fuel valve is re-opened and pressure in the unit
injector decreases at the same time as the fuel injec-
tion to the cylinder stops.
In order to determine when the fuel valve shall open
or close, the control module has access to signals
from sensors and switch contacts.
The control unit is fitted with an atmospheric air pres-
sure sensor and an altitude correction function for
engines operating at high altitudes. This function lim-
its the fuel volume in relation to ambient air pressure.
This is to prevent smoke, high exhaust temperature
and to protect the turbocharger from over-speeding.
Diagnosis function
The task of the diagnosis function is to detect and
locate disturbances within the EMS 2 system, to pro-
tect the engine, and to provide information about
problems that have developed. If a malfunction is dis-
covered, this is announced by warning lamps, a flash-
ing diagnostic lamp or in plain language on the instru-
ment panel, depending on the equipment used. If a
fault code is obtained as a flashing code or in plain
language, this is used for guidance in any trouble-
shooting. Fault codes can also be read by Volvo’s
VODIA tool at authorized Volvo Penta workshops. In
case of serious malfunctions, the engine is shut down
completely, or the control unit reduces the power out-
put (depending on application). A fault code is set as
a guide when fault tracing.

Calculating fuel quantity

The amount of fuel that is sprayed into a cylinder is
calculated by the control module. The calculation
determines the time that the fuel valve is closed (when
the fuel valve is closed fuel is sprayed into the cylin-
der).
The parameters controlling injected amount of fuel
are:
• Requested engine speed
• Motor protector
• Temperature
• Boost air pressure

7748542 10-2009 7
System Information, EMS

In- and out signals

Information from the sensors provides accurate infor-
mation regarding operational conditions and makes it
possible for the control unit processor to calculate the
correct injection amount, injection timing and engine
condition, among many other things.

Input signals
The control unit receives input signals regarding
engine operational conditions along with information
from the following components:
- Coolant temperature sensor
- Charge air pressure/charge air temperature sensors
- Crankcase pressure sensor
- Position sensor
- Camshaft
- Engine speed sensor
- Flywheel
- Piston cooling pressure sensor
- Coolant level sensor
- Oil pressure sensor
- Oil level and oil temperature sensors
- Fuel pressure sensor
- Water-in-fuel sensor
- Air filter pressure sensor
- Air temperature sensor
- Fan speed

Output signals
The control unit uses the input signals to control the
following components:
- Unit injector
- Start motor
- Alternator
- Main relay
- Preheat relay
- Internal EGR (TAD1350-1353GE only)
- Waste gate
- Electronic fan control

8 7748542 10-2009
 System Information, EMS

Instruments
DCU (Display Control Unit)
DCU is a digital instrument panel that communicates
with the engine control unit via the CAN-link. DCU has
several functions, such as:

Engine control
- Start, stop, rpm regulation, preheating, etc.

Monitoring
- Shows engine speed, charge pressure, charge tem-
perature, coolant temperature, oil pressure, oil tem-
perature, engine hours, battery voltage, instantane-
ous fuel consumption and fuel consumption (trip
fuel).

Diagnostic
- Shows fault codes in text. Lists previous faults.

Parameter setting
- Idle speed, alarm limits for oil temperature/coolant
temperature, regulation mode (speed droop/iso-
chronous).

DU (Display Unit)
DU is an instrument for showing the engines operating
values. The values are shown graphically on an LCD
display. The display communicates via the CAN link
and consists of a computerized unit for attachment to
the control panel.
It is connected to the CAN link between the engine
control unit and CIU or DCU.

P0002061

7748542 10-2009 9
System Information, EMS

Location of Sensors

1 2 3

8
4

14

10
13

11
12

P0004318

1. Extra stop 8. Fan, rpm sensor

2. Combined charge air pressure and charge air 9. Under-pressure sensor, air filter
temperature sensor
10. Coolant level sensor, in the expansion tank
3. Oil pressure sensor
11. Coolant temperature sensor
4. Crankcase pressure sensor
12. Piston cooling pressure
5. Water-in fuel sensor
13. Flywheel position and engine speed
6. Combined oil level and oil temperature sensor
14. Camshaft position
7. Fuel pressure sensor

10 7748542 10-2009
12
11
1 2

CAN
J1939
J1587
1708

. + BATT

BATT
HL AB 10 28

STOP

CAN 2
29 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 27

. + BATT SWITCHED
-.
R
W/SB
SB
W
1 2

P0010912
Y/W
GR/Y
SB 2,5
R 2,5
R/BL 1,5
BL
W
W/SB
23 5
31
86
System Information, EMS

6 Y/SB 85
1
1 2 2 1 R/BL 1,5 2 87

Y
R/BL 1,5 30

SB
R 1,5
4
12 3 4 5 6 7 R
3

Y
SB

SB
5
24 8 21

R/BL
Y 1,0
R/BL 1,5
SB SB 2 SB
4 2 SB 1,0
R 1
2P 1 1

22 25 12 15
4 SB SB 4 R/BL 1,0
1 4 SB
R R1 2
3 2 2P 1 P2 1P

30

BN 1,0
GN/SB
GN/W
BL/GN
BL/OR
GN/R
R 1,0
SB 1,0
GR/R
BN/OR
LBN
GR/R
SB 1,0
Y
BL/W
BL/GB
Y 1,0
GN
Y/SB
OR 1,0
R/W
R/BL 1,5
R/BL 1,5
BN 1,0
SB 1,5
SB 1,5
SB 1,5
Y/W
GR/Y
49 3 4 31 11 16 17 18 28 27 23 14 10 8 52 56 30 38 29 25 37 57 60 7 58 59 61 51 55
CONNECTOR B h l h h l

CONNECTOR A b a
SB 2,5
R 2,5
R/BL 1,0

31 11 7 47 22 15 29 35 39 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24 59 62 60 61 8 33 34 27 58 57
- + -
W

BL
BL

SB
GN

OR
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y/SB

R 1,0
W/SB

SB 1,0
SB 1,5

VO/SB

OR/SB
GB/SB
GR/SB

GR/GN
BN/OR

GR/OR
R/BL 1,5

9
R 3
SB SB 2
1 CYL. 1 4 231
P4 4 3 Y 1,0 MAIN RELAY HOLD 4 231

R
26 2 1 Y 1,0
4 CYL. 2 17 19
1
OR 1,0

4 3 Y 1,0
BN 1,0
R/BL 1,0

3 P2 21 21
n n R 25
2 1 Y 1,0
18
Wiring Diagram

13 14 CYL. 3
R/W

R/BL 1,5

20
Y/SB
R 2,5

4 3 Y 1,0
SB 2,5

1 2345 SB 25
2 1 Y 1,0 B+ B- SB 25
4 G M 30
CYL. 4 3 31
4 3 Y 1,0 R 25
BC AE D F
2 1 Y 1,0
2
n CYL. 5
4 3 Y 1,0
1
32 2 1 Y 1,0
CYL. 6
4 3 Y 1,0

2 1 Y 1,0

7748542 10-2009
16
 System Information, EMS

1 Battery (24 V) Cable colors

BL = Blue
2 Main Switch
LBL = Light blue
3 Start motor BN = Brown
LBN = Light brown
4 Alternator
GN = Green
5 Power relay failure GR = Gray
OR = Orange
6 Auxiliary stop
P = Pink
7 Connectors, engine R = Red
SB = Black
8 Sensor, coolant temperature
Vo = Violet
9 Sensors, charge air pressure/charge air temper- W = White
ature Y = Yellow
Wire cross-sectional area = 0.75 mm² unless oth-
10 VODIA socket (diagnostics socket)
erwise stated.
11 Connector (not used)
12 Sensor, crankcase pressure
13 Sensor, camshaft
14 Sensor, flywheel
15 Sensor, piston cooling pressure
16 Unit injectors(cyl. 1-6)
17 Preheat relay
18 Circuit breaker
19 Main circuit breaker 10 A
20 Preheater
21 Sensor, coolant level
22 Sensor, oil pressure/temperature
23 Sensor, water in fuel
24 Sensor, oil pressure
25 Sensor, fuel pressure
26 Air filter indicator
27 Stop button
28 Jumper
29 Internal EGR (TAD1350–1353GE only)
30 Control unit, EMS 2.2
31 Wastegate Valve
32 Electric fan

7748542 10-2009 13
System Information, EMS

CIU (Control Interface Unit)

CIU (Control Interface Unit)

14 7748542 10-2009
 System Information, EMS

1 Key switch, operating current (15+) 16 Alarm, low coolant level

2 RPM-potentiometer 17 Fuel alarm
3 Tachometer (code 14) 18 Diagnostic lamp
4 Oil pressure, instrument 19 Overspeed indication (GE)
5 Oil temperature, instrument 20 Operation indicator
6 Coolant temperature, instrument 21 Preheating indication
7 Instrument illumination 22 Preheating contact
8 Idle contact, two position 23 8-pin Deutsch connecting plug, engine interface
9 1500/1800 contact, two position 24 Governor contact
10 Start switch, spring return 25 Battery voltage alarm
11 Stop switch, spring return 26 Termination resistance 120 Ohm
12 Diagnosis contact, spring return 27 8-pin Deutsch connecting socket
13 Alarm, low oil pressure 28 Contact, engine protector disconnect
14 Alarm, high oil temperature 29 Easy Link connector block
15 Alarm, high coolant temperature 30 Control Interface Unit (CIU)

Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Grey
OR = Orange
P = Pink
R = Red
SB = Black
VO = Purple
W = White
Y = Yellow
Cable cross section =0.75 mm2 unless other-wise stated.

7748542 10-2009 15
System Information, EMS

DCU (Display Control Unit)

12345678 8
11

W/SB
Y/W

R 2,5
GR/Y
SB 2,5

BL 2,5
R/BL 1,5
W
1 Y/W

2 GR/Y

3 SB 2,5

4 R 2,5

5 R/BL 2,5

6 BL 2,5

7 W
W/SB

R/BL 1,5
8

SB 2,5

BL 2,5
W/SB
GR/Y
R 2,5
3

Y/W

W
1 1

1 VO 12345678 9
D 2 4
R/Y
C 2 1 2 3 4 5 6 7 8 10
U SB/Y
3
4 R/BL 5
Y 1
5 3
SB 2
6
7 GN/R

8 GN/Y 6
9 GN/SB
7
10 SB/VO

11 SB/GR

12 SB/W
P0004305

1 Stoppkontakt Kabelfärger
2 Startkontakt BL = Blue
3 1-poligt kontaktdonsblock LBL = Lightblue
BN = Brown
4 Signalhorn, larmsummer LBN = Lightbrown
5 Kontaktblock Easy Link GN = Green
GR = Grey
6 Varvtalspotentiometer OR = Orange
7 Gångindikering P = Pink
R = Red
8 Deutsch 8-poligt kontaktdon, engine interface SB = Black
9 Deutsch 8-poligt kontaktdonshylsa, engine interface VO = Violet
W = White
10 Termineringsmotstånd 120 Ω Cable area = 0.75 mm2 unless
11 DCU (Display Control Unit) otherwise specified.

16 7748542 10-2009
 Control System Installation, Connection

Control System Installation

Connection
General
• The installation must be prepared for well and car-
ried out with the greatest care.
• Secure the connecting cable between the engine
and instrument panel with clamps. Bear in mind that
connector blocks must be mechanically secured so
that they are not exposed to any pulling forces.
• The cables must not be run close by hot engine
components or close to any other heat source.
Ensure that the cables are protected from mechan-
ical wear, sharp edges and water splashes. If nec-
essary, the cables can be run through conduits.
• As far as possible, avoid splices in the system wir-
ing. The cables and any splices must be accessible
for inspection and service.

NOTICE! Connectors must be assembled “dry”, they

must not be filled with petroleum jelly or similar.

7748542 10-2009 17
Control System Installation, Connection

Power supply
NOTICE! The engines are equipped with a 2-pole elec-
trical system. This means that the positive and nega-
tive cables from the battery must be connected to the
starter motor terminals.
The positive cable from the battery may be run via a
main switch to terminal 30 on the starter motor.
The negative cable from the battery must be con-
nected directly to terminal 31 on the starter motor.
Refer to the illustration below.

30

31

P0004300

18 7748542 10-2009
 Control System Installation, Connection

Battery specification
Max. battery 2x220 Ah (series connected), 1150 A
CCA EN.

Battery charging
Standard for all engines is that batteries are supplied
with power from the alternator.

Battery cable cross-sectional area

The total length (L) of the positive and negative cables
determines the cable cross sectional area (A).

Max L (m) 8 10 13
(ft) 26.2 32.8 42.6
Min A (mm2) 70 95 120
(in2) 0.11 0.15 0.19

WARNING!
Due to fire risk, the cable area should never be less
than 70 mm2 (0.1 inch2).

7748542 10-2009 19
Control System Installation, Connection

CIU
TAD1341GE, TAD1342GE, TAD1343GE,
TAD1344GE, TAD1345GE, TAD1350GE,
TAD1351GE, TAD1352GE, TAD1353GE

A E

P0004306

A 8-pin Deutsch connector, from wire harness to engine D For the connection cable, refer to the Instru-
ments page 30 section.
B Connectors, analog instruments E 8-pin Deutsch connector
C 3-pin Deutsch connector, Easy Link instrument F Extension cables, available in the following lengths: 3,
5, 7, 9, and 11 m

20 7748542 10-2009
 Control System Installation, Connection

Engine control
Refer to System Information page 12 CIU
NO = normally open
NC = normally closed

Start lock (system voltage OFF / ON)

Engine system voltage start current (control unit) is 10
A. Ensure that other components in the installation are
dimensioned for this current load.

Start switch
Switch type: closing (NO), spring loaded.

Stop switch
Switch type: closing (NO), spring loaded.

The stop switch is energized during operations via a

parameter setting. In this case use a normally closed
(NC) switch.

RPM potentiometer
Nominal revolutions minus 90 rpm: 0.3–1.9 V (preset
value 1.17 V)
Nominal revolutions plus 90 rpm: 1.9–4.7 V (preset
value 4.5 V)

A
A

1.17 V 2.84 V 4.5 V

P0005827

P0005828

7748542 10-2009 21
Control System Installation, Connection

1800 rpm switch

Two-position contact.

Idle switch
Two-position contact.
Closed contact provides idle rpm (900 rpm).

Droop value switch

Two-position contact.
The switch must be closed to provide rpm droop value.

Primary control switch

Two-position contact.

Contact, pre-heating
Two-position contact.

22 7748542 10-2009
 Control System Installation, Connection

CIU
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE

A 8-pin Deutsch connector, from wire harness to engine D For the connection cable, refer to the Instru-
ments page 30 section.
B Connectors, analog instruments E 8-pin Deutsch connector
C 3-pin Deutsch connector, Easy Link instrument F Extension cables, available in the following lengths:
3, 5, 7, 9, and 11 m

7748542 10-2009 23
Control System Installation, Connection

Engine control
Refer to System Information page 12 CIU
NO = normally open
NC = normally closed

A Start lock
The start lock switch is used to connect the system
power, pre-heating and start and stop functions.

B Engine system voltage start current (control unit) is 10

A. Ensure that other components in the installation are
dimensioned for this current load.

P0003965

A Stop contact
B ON contact
C Start lock
D Pre-heating contact

Start lock positions

I
Position 0: engine switched OFF
Position I: system voltage ON
Position II: pre-heating ON (spring return)
Position III: start motor ON (spring return)
Position S: stop function ON (spring return)

A
B
C
D
P0003966 E

A Pre-heating
B Start
C Batt +
D 15 start lock
E Stop

24 7748542 10-2009
 Control System Installation, Connection

Control switch
Two-position contact.

Accelerator pedal
Idle: 0.3 1.9 V (preset value 1.17 V)
Full throttle: 1.9 4.7 V (preset value 4.5 V)

If an accelerator pedal with different resistance and

voltage values is used, the control unit must be re-cali-
brated using the parameter tool; refer to Connection of
special tool VODIA page 34.

Idle switch
The accelerator pedal has an integral idle switch that
acts as an emergency device if the accelerator pedal
A potentiometer becomes defective.

When the accelerator pedal is depressed, a contact is

B closed and the engine increases in steps to 80 percent
of maximum rpm. When the accelerator pedal is
released, the contact is opened and the engine slows
to idle immediately.

P0004058

7748542 10-2009 25
Control System Installation, Connection

DCU

C
A

P0005826

A 8-pin connector from the engine wire harness.

B 3-pin Deutsch connector, Easy Link instrument
C Connectors, analog instruments (options)

26 7748542 10-2009
 Control System Installation, Connection

DCU (Display Control Unit)

The DCU is connected via the 8-pin databus connector
block.

Display (optional)
Switch type: closing (NO), spring loaded.

Stop switch (optional)

Switch type: closing (NO), spring loaded.

Warning and control lamps (options)

Running indication:
Max. power 3 W
Voltage 24 V

7748542 10-2009 27
Control System Installation, Connection

Rpm-potentiometer
TAD1341GE, TAD1342GE, TAD1343GE,
TAD1344GE, TAD1345GE, TAD1350GE,
TAD1351GE, TAD1352GE, TAD1353GE

The values from the rpm potentiometer in-I or output

signal from the connection to an external load distri-
bution system can be set in the DCU.
Nominal revolutions minus 120 rpm: 0–10 V (preset
value 1 V)
Nominal revolutions plus 120 rpm: 0–10 V (preset
value 9 V)
It is possible to invert the signal; see diagram.

A A

B
B

C C
1V 5V 9V 1V 5V 9V
P0005824
P0005825

A Nominal revolutions + 120 rpm A Nominal revolutions + 120 rpm

B Nominal revolutions (1500/1800 rpm) B Nominal revolutions (1500/1800 rpm)
C Nominal revolutions - 120 rpm C Nominal revolutions - 120 rpm

Rpm-potentiometer
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE

It is possible to invert the signal; see the diagram

below.

P0005815
P0005816

Max. potentiometer value: 0–10 V (preset value 9V)

Min. potentiometer value: 0–10 V (preset value 1V)

28 7748542 10-2009
 Control System Installation, Connection

Warning and Indication Lamps

TAD1341GE, TAD1342GE, TAD1343GE,
TAD1344GE, TAD1345GE, TAD1350GE,
TAD1351GE, TAD1352GE, TAD1353GE

The warning and control lamps below are available.

Specification for all lamps:

Max. power 3 W
Voltage 24 V

Refer to the CIU System Information page 12.

• Alarm, low oil pressure
• Alarm, high oil temperature
• Alarm, high coolant temperature
• Alarm, low coolant level
• Alarm, low fuel level
• Alarm, low battery voltage
• Diagnostic lamp
• Pre-heat indicator

Warning and Indication Lamps

TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE

The warning and control lamps below are available.

Specification for all lamps:

Max. power 3 W
Voltage 24 V

Refer to the CIU System Information page 12.

• Alarm, low oil pressure
• Alarm, high oil temperature
• Alarm, high coolant temperature
• Alarm, low coolant level
• Alarm, low fuel level
• Alarm, low battery voltage
• Diagnostic lamp
• Pre-heat indicator

7748542 10-2009 29
Control System Installation, Connection

Instruments
Easy Link Instrument (option)
Refer to the System Information page 12 for the appli-
cable engine.

For parallel connection of up to 20 extra VDO instru-

ments.
The instruments will automatically find their own
parameter group from the databus. Maximum Easy
Link cable length is 3 m.

The following instruments are available:

• Tachometer/operating hours
• Coolant temperature
• Oil pressure
P0005054

• Oil temperature
• Battery voltage

Retaining collar Retaining bracket

P0005053

P0005052

Extension cable, 3-pole, 1 m

P0005051

A 3-pin connector
B 3-pole connector
C CIU wiring harness

30 7748542 10-2009
 Control System Installation, Connection

Instrument, analog (option)

Refer to the System Information page 12 for the appli-
cable engine.

Tachometer
Use Volvo Penta standard tachometer, graduations 0–
2,600 rpm.
Setting code 14. Refer to installation instructions.

P0003961

Oil pressure gauge

Use Volvo Penta oil pressure gauge, graduations 0–
10 bar (0–145 psi).

P0003961

Oil temperature gauge

Use Volvo Penta oil temperature gauge, graduations
40–150 °C (104–302 °F).

P0003961

7748542 10-2009 31
Control System Installation, Connection

Coolant temperature gauge

Use Volvo Penta oil temperature gauge, graduations
40–150 °C (105–300 °F).

Diagnostics switch
Switch type: closing (NO), spring loaded. For reading
fault codes, refer to the Control System Installa-
tion page 40 chapter.

Contact, pre-heater
Switch type: closing (NO), spring loaded. This contact
activates the pre-heating.

P0003961

32 7748542 10-2009
 Control System Installation, Connection

Synchronizing Engine Speed

Synchronization/load distribution
The system is adapted for GAC synchronization and
load distribution. Use the EAM122 interface module
when connecting to this system. When this system is
used, voltage levels must be adjusted simultaneously
with VODIA, according to the below.

NOTICE! The EAM122 interface module is not sold by

Volvo Penta. Contact a GAC (Governors of America
Corporation) dealership.

A
B A
C

0.7 V 2.75 V 4.8 V

P0005829

A Nominal revolutions +120 rpm

B Nominal revolutions (1500/1800 rpm)
C Nominal revolutions –120 rpm
P0003964

A Rpm control (GN/NO)

B Rpm control (GN/SB)
C Contact to (R/BL 1.5)

7748542 10-2009 33
Control System Installation, Parameter Setting

Parameter Setting
Connection of special tool VODIA
Connection of special tool VODIA

P0001169

Function
It is possible to read and adjust parameters with the
VODIA tool, part no.3838619, as described in the fol-
lowing pages.

The VODIA tool is connected to the diagnostic outlet

6-pin connector located on the left side of the engine.
Refer to the VODIA user directions for instructions.

34 7748542 10-2009
 Control System Installation, Parameter Setting

Adjustable parameters
TAD1341GE, TAD1342GE, TAD1343GE,
TAD1344GE, TAD1345GE, TAD1350GE,
TAD1351GE, TAD1352GE, TAD1353GE

NOTICE! Some parameters require special authoriza-

tion.

Primary regulator mode Indicated engine rpm inverted value

Selects the regulator to be used when the regulator
contact is closed.
Alternative modes: ”Isochronous” or ”Droop value”
Preset mode: ”Isochronous”
Selects the regulator to be used when the regulator
contact is closed.
Alternative engine revolutions: 1500 rpm or 1800
rpm.
Preset rpm: dependent on the specification ordered.

PTO regulator gradient is used Maximum engine revolutions (CIU)

The gradient is defined either by a droop value in per- Potentiometer signal voltage on the CIU unit corre-
cent if the Regulator roop value parameter is equal to sponding to nominal revolutions (1500/1800 rpm) plus
zero or Nm/rpm if the Regulator gradient parameter is +/- 90 rpm.
equal to zero. Min. value: 1.90 V
Max. value: 4.70 V
Preset value: 4.50 V

Regulator droop value Pre-heating for ignition

Selects the droop value magnitude to be used when Selects whether pre-heating and post heating is to be
droop value is activated (percent). activated directly when the ignition is turned on.
Min. value: 0 % The pre-heating and post heating periods are depend-
Max. value: 8 % ent on coolant temperature.
Preset value: 4 % If the parameter is in ”Off” mode, pre-heating and post
heating must be activated manually via the ignition
lock or pre-heater button.
Alternative modes: “Off” or “On”
Preset mode: “Off”

Stop function Lamp test

The CIU unit stop signal is energized during “opera- This parameter determines if a lamp test is to be per-
tions” or “stop”. formed when the system is started.
Preset mode: ”Stop” Alternative modes: “Off” or “On”
Preset mode: “On”

Idling speed
Setting idle revolutions.
Min. value: 600 rpm
Max. value: 1200 rpm
Preset value: 900 rpm

7748542 10-2009 35
Control System Installation, Parameter Setting

Adjustable parameters
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE

NOTICE! Certain parameters require special authori-

zation.

Regulator mode Regulator gradient

Select if droop value is active. Determines the droop value to be used (gradient)
Alternative modes: “Off” or “No” Min. value: 10 Nm/revolution
Preset mode: ”No” Max. value: 128 Nm/revolution
Preset value: 25 Nm/revolution

Inverted regulator mode Primary regulator mode

Select if droop value is to be active. Selects the regulator to be used when the regulator
Alternative modes: “No droop value” or “Variable contact is closed.
droop value” Alternative modes: ”Isochronous” or ”Droop value”
Preset mode: “Fixed droop value” Preset mode: ”Isochronous”

Idling speed Idle voltage (CIU)

Setting idle revolutions. Throttle control input signal voltage to corresponding
Min. value: 600 rpm idle at the CIU unit.
Max. value: 900 rpm Min. value: 0.30 V
Preset value: 700 rpm Max. value: 1.90 V
Preset value: 1.17 V

Voltage max. rpm (CIU) Pre-heating for ignition

Throttle control input signal voltage to corresponding Selects if pre-heating is to be activated directly the
full throttle at the CIU unit. ignition is turned on. If the parameter is in ”Off” mode,
Min. value: 1.90 V pre-heating and post heating must be activated man-
Max. value: 4.70 V ually via the ignition lock or pre-heater button.
Preset value: 4.50 V Alternative modes: “Off” or “On”
Preset mode: “Off”

Stop function CIU stop function

Preset mode: ”Stop” The CIU unit stop signal is energized during “Opera-
tions” or “Stop”.
Preset mode: ”Stop”

Lamp test
This parameter determines if a lamp test is to be per-
formed when the system is started.
Alternative modes: “Off” or “On”
Preset mode: “On”

36 7748542 10-2009

Alarm threshold, high oil temperature
A warning lamp is lit at this temperature.
Min. value: 120 °C (248 °F)
Preset value: 125 °C (257 °F)
Max. value: 130 °C (266 °F)
Alarm threshold, high coolant temperature
A warning lamp is lit at this temperature.
Min. value: 95 °C (203 °F)
Preset value: 102 °C (216 °F)
Max. value: 103 °C (217 °F)
Alarm threshold, high oil temperature
A warning lamp is lit at this temperature.
Min. value: 120 °C (248 °F)
Preset value: 125 °C (257 °F)
Max. value: 130 °C (266 °F)
7748542 10-2009
Control System Installation, Parameter Setting
Alarm limits
TAD1350GE, TAD1351GE, TAD1352GE
Overspeed limit
Percent above normal revolutions at which the over-
speed warning is activated.
Min. value: 0 %
Preset value: 20 %
Max. value: 20 %
Alarm limits
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE
Alarm threshold, high coolant temperature
A warning lamp is lit at this temperature.
Min. value: 95 °C (203 °F)
Preset value: 102 °C (216 °F)
Max. value: 103 °C (217 °F)
37
Control System Installation, Parameter Setting
Oil temperature
Determines whether engine protection is to be acti-
vated in respect of high oil temperature. A fault code
is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Coolant temperature
Determines whether engine protection is to be acti-
vated in respect of high coolant temperature. A fault
code is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Coolant level
Determines whether engine protection is to be acti-
vated in respect of low coolant level. A fault code is
registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Charge air temperature
Determines whether engine protection is to be acti-
vated in respect of high charge air temperature. A fault
code is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Charge pressure
Determines whether engine protection is to be acti-
vated in respect of high charge air pressure. A fault
code is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
38
Engine protection
TAD1341GE, TAD1342GE, TAD1343GE,
TAD1344GE, TAD1345GE, TAD1350GE,
TAD1351GE, TAD1352GE, TAD1353GE
Oil pressure
Determines whether engine protection is to be acti-
vated in respect of low oil pressure. A fault code is
registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Piston cooling pressure
Determines whether engine protection is to be acti-
vated in respect of low piston cooling pressure. A fault
code is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Crankcase pressure
Determines whether engine protection is to be acti-
vated in respect of high crankcase pressure. A fault
code is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Overspeed warning shutdown
Determines whether engine protection is to be acti-
vated in respect of overspeed. A fault code is regis-
tered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
7748542 10-2009

Oil temperature
Determines whether engine protection is to be acti-
vated in respect of high oil temperature. A fault code
is registered and the engine is shut down.
TAD1650VE: a fault code is registered and an orange
or red warning lamp is lit.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Coolant temperature
Determines whether engine protection is to be acti-
vated in respect of high coolant temperature. A fault
code is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Coolant level
Determines whether engine protection is to be acti-
vated in respect of low coolant level. A fault code is
registered and the engine is shut down.
TAD1650VE: a fault code is registered and an orange
warning lamp is lit.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Charge air temperature
Determines whether engine protection is to be acti-
vated in respect of high charge air temperature. A fault
code is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Charge pressure
Determines whether engine protection is to be acti-
vated in respect of high charge air pressure. A fault
code is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
7748542 10-2009
Control System Installation, Parameter Setting
Engine protection
TAD1340VE, TAD1341VE, TAD1342VE,
TAD1343VE, TAD1344VE, TAD1345VE
Oil pressure
Determines whether engine protection is to be acti-
vated in respect of low oil pressure. A fault code is
registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Piston cooling pressure
Determines whether engine protection is to be acti-
vated in respect of low piston cooling pressure. A fault
code is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
Crankcase pressure
Determines whether engine protection is to be acti-
vated in respect of high crankcase pressure. A fault
code is registered and the engine is shut down.
Alternative modes: “Yes” or “No”
Preset mode: “Yes”
ECU temperature
Determines whether engine protection is to be acti-
vated in respect of high control unit temperature. A
fault code is registered and an orange or red warning
lamp is lit.
39
Control System Installation, Diagnostic Function

Diagnostic Function
The diagnostic function monitors and controls that the
EMS system functions normally. The diagnostic func-
tion has the following tasks:
• Detecting and locating disturbances
• Reporting detection of disturbances
• Providing guidance when fault tracing
NOTICE! With the DCU:n it is possible choose the lan-
guage that the inform-tion is presented in.

If the diagnostic function detects a disturbance in the

system, this is reported using fault codes via the instru-
ments.
Both active (unrectified) and passive (rectified) faults
are stored in the control unit.
Refer to the “Operation” heading for reading fault
codes/fault messages.
All fault codes and fault messages are found in the fault
code list, with information about the reason, reaction
and measures to be taken. Refer to Fault Code Reg-
ister.

NOTICE! All instruments are optional.

Effect on engine
Engines are affected differently, depending on the
severity of the fault discovered by the diagnostic func-
tion.
A fault message in the form of a fault code is always
generated when a malfunction is discovered by the
diagnostic function.
Engines are affected differently, depending on the
severity of the fault:
• The engine is not affected
• Engine goes to idle
• Engine torque is restricted to a certain amount
• Engine is stopped

40 7748542 10-2009
 Control System Installation, Diagnostic Function

Active and Inactive Faults

Active faults
At the same time, the fault is stored in the control unit
memory. When the fault has been attended to and the
ignition is switched off and on again, the fault disap-
pears as active.
DCU (Display Control Unit)
• text !! ENGINE WARNING !! shown on the dis-
play.
Inactive faults
• DCU – the fault is indicated as passive
• CIU – the diagnostic lamp goes out
• DU – the fault message disappears (inactive
faults cannot be read out)
• “Easy Link” – the lamp on the alarm panel goes
out

CIU (Control Interface Unit)

• the diagnostic lamp starts to flash.
• ”Easy Link” instrument
- the relevant lamp on the alarm panel lights up
- after the diagnostic button has been pressed,
the fault code is shown as text on the tachometer
display.

DU (Display Unit)
• Either WARNING! or ALARM STOP (a buzzer
sounds) will be shown on the display, depending
on the severity of the fault.

• Fault codes can also be read off using the

VODIA tool. For instructions, see “VODIA User’s
Guide”.

Operation
When a malfunction has occurred and the diagnostic Reading fault codes via the DU (Display Unit)
system has generated one or more fault codes, these Depending on the severity of the fault the text, either
are read out differently depending on the equipment WARNING! or ALARM STOP (a buzzer sounds) will
used. Please refer to “Fault code messages”. be shown on the display
If the system indicates that a fault code has been
1 Press any button to come to the fault list. The
set:
fault list shows operation hours and fault mes-
1 Cut engine speed to idle, or shut the engine off. sage.
2 For DCU/DU 2 Look up the fault code in Fault Code Register
Read the fault code from the display, please and take the recommended measures.
refer to Reading fault codes via the DCU or
3 Press on ACK to acknowledge the fault code.
Reading fault codes via the DU.
The display background will change color (the
For CIU
buzzer stops sounding).
press the diagnostic button and read the fault
code, by observing the flashing of the diagnostic 4 Press on EXIT to leave the fault list.
lamp. Refer to Reading fault codes via the
diagnostic lamp, CIU.
3 Look up the fault code in the Fault Code Regis-
ter chapter and take the recommended meas-
ures.

7748542 10-2009 41
Control System Installation, Diagnostic Function

Reading fault causes via the DCU (Display Control Reading fault codes via an “Easylink” instrument
Unit) When the system has discovered a malfunction, this
When a fault code is set, the following text is shown is reported by the diagnostic lamp which starts to
on the display: flash.
!! ENGINE WARNING !!
1 Press the diagnostic button. The fault code is
alternated withPress SEL for information.
shown as text on the tachometer display.
Read the fault code as follows:
2 Look up the fault code in the Fault Code Regis-
1 Press SEL-button to come to the fault list.
ter chapter and take the recommended meas-
The fault list shows:
ures.
-Operation hours
-Fault message 3 When the fault has been rectified, the fault code
-Active/inactive disappears from the display and the diagnostic
lamp goes out.
2 Look up the fault code in theFault Code Regis-
ter chapter and take the recommended meas-
ures.
3 Press ESC-button to leave the fault list.

NOTICE! To enter the fault list when no fault code has

been set, press the SEL button and select Diagnos-
tics from the menu.

Reading fault codes via the diagnostic lamp on Erasing fault codes
the instrument panel, CIU Fault codes must be erased by an authorized Volvo
When the system has discovered a malfunction, the Penta workshop by means of the VODIA tool.
diagnostic lamp starts to flash. If the diagnostic button
is depressed and then released, a fault code is
flashed out.
The fault code consists of two groups of flashes, sep-
arated by a pause of two seconds. A fault code is
obtained by counting the number of flashes in each
group
Example: paus = Fault Code 2.4
The fault code is stored and can be read as long as
the malfunction remains. You can find information
about cause, reaction and actions in the Fault Code
Register chapter.
Read the fault code as follows:
1 Press the diagnostic button.
2 Release the diagnostic button and make a note
of the fault that is flashed out.
3 Repeat items 1-2. A new fault code is flashed ou
tif more are stored. Repeat until the first fault
code is repeated.

NOTICE! When the first fault code reoccurs, all the

fault codes have been read.
If the diagnostics button is depressed after the fault
has been corrected and the fault code deleted, the
code 1.1, No fault, will be shown.

42 7748542 10-2009
 Control System Installation, Fault Code Register

Fault Code Register

CAUTION!
Read through the safety advice before starting any work.

The fault codes below comprise:

- a fault text message displayed when a DCU or DU is installed.

- a flash code, e.g. 5.4, read off from the diagnostics lamp; refer to Control System Installation page 40
- a fault code, e.g. PID 45, read off from the VODIA tool.

For references to sleeves in electrical connectors, refer to System Information page 12.

No fault (Code 1.1)

Cause Reaction Remedy
There are no active faults.

Water in Fuel (Code 2.1, PID/SPN 97)

Cause Reaction Remedy
• Water in fuel • None • Empty the primary fuel filter

Coolant Level (Code 2.2, PID/SPN 111)

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

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

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

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

Cause Reaction Remedy
• No signal • Engine is very difficult to start • Check that the sensor con-
and runs roughly when it nector is correctly installed
• Abnormal frequency
starts
• Check that the engine speed
• “Intermittent” signal from the
sensor cable is not damaged
sensor
• Check that the engine speed
• Fault in sensor
sensor is correctly installed in
the flywheel housing
• Check engine speed sensor
function

7748542 10-2009 43
Control System Installation, Fault Code Register

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

Cause Reaction Remedy
• No signal • Engine takes longer to start • Check that the engine speed
than normal. Engine runs nor- sensor connector is correctly
• Abnormal frequency
mally when running installed
• Fault in sensor
• Check that the engine speed
sensor cable is not damaged
• Check that the engine speed
sensor is correctly installed in
the upper timing gear cover.
• Check engine speed sensor
function.

Engine Speed (Code 2.6, PID/SPN 190)

Cause Reaction Remedy
• Engine speed too high • None • After the engine has stopped,
look for the reason for the high
speed

Speed Potentiometer Connected to CIU (Code 2.8, PPID 132/SPN 91, 608,)
Cause Reaction Remedy
• Shorted to plus (+) or minus • Engine goes to idle • Check that the potentiometer
(-) has been connected correctly
• Speed feezes
• Fault in sensor • Check that the cable harness
to the potentiometer has not
been damaged
• Check the potentiometer
function

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

Cause Reaction Remedy
• Short circuit • None • Check the indicator cables for
breaks and short circuits
• Open circuit
• Check indicator function.
• Fault in indicator
Change indicator as neces-
sary

Oil Pressure Sensor (Code 3.1, PID/SPN 100)

Cause Reaction Remedy
• Short circuit to positive (+) or • None • Check that the oil pressure
earth (ground) (–) sensor cable is not damaged
• Open circuit • Check that the oil pressure
sensor is correctly connected

44 7748542 10-2009
 Control System Installation, Fault Code Register

Boost Temperature Sensor (Code 3.2, PID/SPN 105)

Cause Reaction Remedy
• Short circuit to positive (+) or • None • Check that the boost temper-
earth (ground) (–) ature sensor connector is cor-
rectly installed
• Open circuit
• Check that the boost temper-
ature sensor cable is not dam-
aged
• Check that the boost temper-
ature sensor is correctly
installed
• Check boost temperature
sensor function

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

Cause Reaction Remedy
• Short circuit to positive (+) or • Preheating is also activated • Check that the coolant tem-
earth (ground) (–) when the engine is hot perature sensor connector is
correctly installed
• Open circuit
• Check that the coolant tem-
perature sensor cable is not
damaged
• Check that the coolant tem-
perature sensor is correctly
installed
• Check coolant temperature
sensor function

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

Cause Reaction Remedy
• Short circuit to positive (+) or • Engine smokes more than • Check that the boost pressure
earth (ground) (–) normally during acceleration/ sensor connector is correctly
load increase installed
• Open circuit
• Check that the boost pressure
sensor cable is not damaged
• Check that the boost pressure
sensor is correctly installed
• Check boost pressure sensor
function

7748542 10-2009 45
Control System Installation, Fault Code Register

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

Cause Reaction Action
• High charge pressure • Engine power is reduced or • Check that the charge air
engine stops. pressure sensor connector is
correctly installed
• Check that the charge air
pressure sensor cable is not
damaged
• Check that the charge air
pressure sensor is correctly
installed
• Check charge air temperature
sensor function

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

Cause Reaction Remedy
• Short circuit to positive (+) or • None • Check that the fuel pressure
earth (ground) (–). sensor connector is correctly
installed.
• Open circuit.
• Check that the fuel pressure
sensor cable is not damaged.
• Check that the fuel pressure
sensor is correctly installed.
• Check fuel pressure sensor
function.

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

Cause Reaction Remedy
• Shorted to plus (+) or minus • None • Check that the cable harness
(-) to the oil temperature sensor
has not been damaged
• Break
• Check that the oil tempera-
ture sensor has been con-
nected correctly

Fuel Pressure (Code 3.8, PID/SPN 94)

Cause Reaction Remedy
• Low supply pressure • None • Check if it is possible to build
up pressure with the hand
pump
• Check the fuel filter
• Check the fuel pre-filter

Battery Voltage, EMS (Code 3.9, PID/SPN 158)

Cause Reaction Remedy
• Faulty alternator • None • Check the supply voltage
from the control unit
• Faulty battery, battery cables

46 7748542 10-2009
 Control System Installation, Fault Code Register

Start output/Start motor relay (Code 4.6, PPID 3/ SPN 677)

Cause Reaction
• Shorted to plus (+) or minus • The engine cannot be started
(-)
• The engine starts immedi-
• Activated for too long ately when ignition is turned
on
Remedy
• Check that connections to the
ignition key/start panel have
not been damaged
• Check that the cable harness
to the ignition key/sart panel
has not been damaged

Stop Input EMS (Code 4.8, PPID 6/SPN 970)

Cause Reaction Remedy
• Short circuit to negative (-) • Engine can only be stopped • Check that the starter switch
with the auxiliarystop connections are not damaged
• Open circuit

Starter Input CIU (Code 5.2, PPID 4/SPN 520194)

Cause
• Shorted to minus (-)
• Activated for too long
Reaction
• The engine cannot be started
• The engine starts immedi-
ately when ignition is turned
on
Remedy
• Check that connections to the
ignition key/start panel have
not been damaged
• Check that the cable harness
to the ignition key/start panel
has not been damaged

Stop Input CIU (Code 5.3, PPID 6/SPN 52095)

Cause
• Short circuit to negative (-)
• Open circuit
• Activated for too long time
Reaction Remedy
• Engine can only be stopped • Check that the starter switch
with the auxiliary stop (AUX connections are not damaged
STOP) on engine
• Check that the ignition switch
• Engine stops. A fault code is cable is not damaged
displayed for 40 seconds and
the engine can not be started
during this time. When a fault
code is active, the engine can
be started but not stopped

Preheating Relay (Code 5.4, PID 45/SPN 626)

Cause Reaction Remedy
• Short circuit to positive (+) or • Preheating can not be acti- • Check that the relay input
earth (ground) (–). vated. cable is not damaged.
• Open circuit. • Preheating is constantly con- • Check relay function.
nected.

Air Filter Pressure (Code 5.5, PID/SPN 107)

Cause Reaction Remedy
• Too large pressure drop • Less good response from • Check the air filter
across filter engine

7748542 10-2009 47
Control System Installation, Fault Code Register

Air Filter Sensor (Code 5.6, PID/SPN 107)

Cause Reaction Remedy
• Shorted to plus (+) or minus • None • Check that the air filter sensor
(-) contact is correctly installed
• Break • Check that the cable harness
to air filter sensor has not
been damaged
• Check the air filter sensor
functionality

Oil Level (Code 5.7, PID/SPN 98)

Cause Reaction Remedy
• Oil level to low • None • Check the oil level

Oil Temperature (Code 5.8, PID/SPN 175)

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

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

Cause Reaction Remedy
• Shorted to plus (+) or minus • None • Check that the cable harness
(-) to the oil level sensor has not
been damaged
• Break
• Check the oil level sensor
function

Coolant Temperature (Code 6.1, PID/SPN 110)

Cause Reaction
• Coolant temperature is too • Engine control module
high reduces engine power
(unless the protection has
been shut off with the VODIA
diagnostic tool)
Remedy
• Check the coolant level
• Check the charge air cooler
(cleanliness)
• Check if there is air in the
cooling system
• Check the pressure cap on
the expansion tank
• Check coolant temperature
sensor function
• Check thermostat function

Boost Temperature (Code 6.2, PID/SPN 105)

Cause Reaction
• Boost temperature is too high • Engine control module
reduces engine power
(unless the protection has
been shut off with the VODIA
diagnostic tool)
Remedy
• Check the coolant level
• Check the charge air cooler
(cleanliness)
• Check boost temperature
sensor function
• Check the function of the ther-
mostat

48 7748542 10-2009
 Control System Installation, Fault Code Register

Data Link (CAN), CIU (Code 6.4, SID 231/SPN 639)

Cause Reaction
• Faulty data link (CAN), , CIU • Instruments and warning
lamps stop working
Remedy
• Check that the 8-pin connec-
tor is not damaged
• Check that the cables
between the CIU and the
engine management unit are
not damaged

Data Link (CAN), EMS 2 (Code 6.5, SID 231/SPN 639/2017/PSID 201)
Cause Reaction
• Internal fault in control mod- • Engine not operating: engine
ule can not be started. Engine
operating: engine idles and
can only be stopped with the
auxiliary stop (AUX-stop)
Remedy
• Check that the 8-pin connec-
tor is not damaged
• Check that the cables
between the CIU and the
engine management unit are
not damaged
• Check that sleeves 11 and 12
in the connector on the CIU
are not damaged

Oil Pressure (Code 6.6, PID/SPN 100)

Cause Reaction
• Oil pressure is too low • Engine control module
reduces engine power
(unless the protection has
been shut off with the VODIA
diagnostic tool)
Remedy
• Check oil level
• Check that the air filter is not
blocked
• Check system pressure
valves and safety valves in
the oil system
• Check oil pressure sensor
function

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

Cause Reaction Remedy
• Piston cooling pressure is too • Engine stopped • Check that the oil pressure in
low the engine exceeds175 kPa
(25.4 psi)

Piston Cooling Pressure Sensor (Code 6.8, PPID 8/SPN 520192)

Cause Reaction Remedy
• Shorted to plus (+) or minus • None • Check that the piston cooling
(-) pressure sensor contact is
correctly installed
• Break
• Check that the cable harness
to the piston cooling pressure
sensor has not been dam-
aged
• Check the piston cooling
pressure sensor functionality

7748542 10-2009 49
Control System Installation, Fault Code Register

Battery Voltage, CIU (Code 6.9, PID/SPN 158)

Cause
• Short circuit to negative (-)
• Faulty alternator
• Faulty battery, battery cables
Reaction
• Problems in engine starting
Remedy
• Check the supply voltage
from the control unit
• Check the batteries
• Check the alternator
• Check the 8-pin contact

SInjector, Cylinder #1 (Code 7.1, SID 1/SPN 651)

Cause Reaction Remedy
• Electrical fault • Engine runs on 5 cylinders • Check that the injector cables
are not damaged
• Faulty compression or injec- • Abnormal sound
tor • Check that the injector con-
• Reduced performance
nections are not damaged
• Check fuel supply pressure
• Check the valve clearance
• Do a compression test and
check cylinder #1

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

Cause Reaction Remedy
• Electrical fault • Engine runs on 5 cylinders • Check that the injector cables
are not damaged
• Faulty compression or injec- • Abnormal sound
tor • Check that the injector con-
• Reduced performance
nections are not damaged
• Check fuel supply pressure
• Check the valve clearance
• Do a compression test and
check cylinder #2

Injector, Cylinder #3 (Code 7.3, SID 3/SPN 653)

Cause Reaction Remedy
• Electrical fault • Engine runs on 5 cylinders • Check that the injector cables
are not damaged
• Faulty compression or injec- • Abnormal sound
tor • Check that the injector con-
• Reduced performance
nections are not damaged
• Check fuel supply pressure
• Check the valve clearance
• Do a compression test and
check cylinder #3

50 7748542 10-2009
 Control System Installation, Fault Code Register

Injector, Cylinder #4 (Code 7.4, SID 4/SPN 654)

Cause Reaction Remedy
• Electrical fault • Engine runs on 5 cylinders • Check that the injector cables
are not damaged
• Faulty compression or injec- • Abnormal sound
tor • Check that the injector con-
• Reduced performance
nections are not damaged
• Check fuel supply pressure
• Check the valve clearance
• Do a compression test and
check cylinder #4

Injector, Cylinder #5 (Code 7.5, SID 5/SPN 655)

Cause Reaction Remedy
• Electrical fault • Engine runs on 5 cylinders • Check that the injector cables
are not damaged
• Faulty compression or injec- • Abnormal sound
tor • Check that the injector con-
• Reduced performance
nections are not damaged
• Check fuel supply pressure
• Check the valve clearance
• Do a compression test and
check cylinder #5

Injector, Cylinder #6 (Code 7.6, SID 6/SPN 656)

Cause Reaction Remedy
• Electrical fault • Engine runs on 5 cylinders • Check that the injector cables
are not damaged
• Faulty compression or injec- • Abnormal sound
tor • Check that the injector con-
• Reduced performance
nections are not damaged
• Check fuel supply pressure
• Check the valve clearance
• Do a compression test and
check cylinder #6

Crankcase Ventilation Pressure (Code 7.7, PID/SPN 153)

Cause Reaction
• Crankcase ventilation pres- • The engine is shut down (if
sure too high the protection has notbeen
shut off by the parameter tool)
Remedy
• Check whether the crankcase
ventilation is blocked
• Check whether cylinder lin-
ers, pistons or piston rings are
worn or damaged

7748542 10-2009 51
Control System Installation, Fault Code Register

Crankcase Ventilation Pressure Sensor (Code 7.8, PID/SPN 153)

Cause Reaction Remedy
• Shorted to plus (+) or minus • None • Check that the crankcase
(-) ventilation pressure sensor
contact is correctly installed
• Break
• Check that the cable harness
to the crankcase ventilation
pressure sensor has not been
damaged
• Check that the crankcase
ventilation pressure sensor
correctly installed
• Check crankcase ventilation
pressure sensor function

Air Temperature Sensor, Inlet (Code 7.9, PID/SPN 172)

Cause Reaction Remedy
• Shorted to plus (+) or minus • None • Check that the air tempera-
(-) ture sensor contact is cor-
rectly installed
• Break
• Check that the cable harness
to the air temperature sensor
has not been damaged
• Check that the air tempera-
ture sensor is correctly instal-
led
• Check the air temperature
sensor functionality

Injection Pressure (Code 8.3, PID/SPN 164)

Cause Reaction Remedy
• Fault in fuel supply • Warning lamp lights up • Check harness
• Fault in fuel pump • Control unit reduces engine • Check sensor
power
• Fault in harness • Check fuel filter
• Fault in sensor • Check fuel pump

Injection Pressure, Regulator (Code 8.3, SID 42/SPN 679)

Cause Reaction Remedy
• Faulty cables • Control unit reduces engine • Contact an authorized Volvo
power Penta workshop
• Faulty actuator
• Fault in MPROP

Pressure in Distribution Manifold (Code 8.3, PSID 96/SPN 1239)

Cause Reaction Remedy
• Leakage in the high pressure • Control unit reduces engine • Contact an authorized Volvo
fuel system power Penta workshop
• Leakage in the high pressure
supply pipe to the injector

52 7748542 10-2009
 Control System Installation, Fault Code Register

Pressure Valve (Code 8.3, PSID 97/SPN 679)

Cause Reaction Remedy
• Leakage in the PRV (Pres- • Control unit reduces engine • Contact an authorized Volvo
sure Release Valve) power Penta workshop
• The PRV stuck closed
• The PRV stuck open

ECU Temperature (Code 8.4, PPID 55/SPN 1136)

Cause Reaction Remedy
• Control unit too hot, incorrect • None • Check the control unit instal-
assembly lation. Recommended ambi-
ent temperature is 50°C
• Electrical fault, damaged sen-
(122°F)
sor

TAD1350GE, TAD1351GE, TAD1352GE,

TAD1353GE

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

Cause
• Fault in cable harness (boost
pressure sensor)
• Mechanical fault on the IEGR
Reaction
• Engine control module
reduces engine power
Remedy
• Check cable harness (boost
pressure sensor)
• Check the IEGR
• Contact a Volvo Penta
authorized workshop

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

Cause Reaction Remedy
• Fault in cable harness • Preheating can not be acti- • Check the cable harness
vated
• Fault in preheating relay • Check the preheating relay

Faulty data link (J1587) (Code 9.2, SID 250/SPN 608)

Cause Reaction Remedy
• Faulty data link • None • Check that the 8-pin connec-
tor is not damaged
• Check that the cables
between the CIU/DCU and
the engine management unit
are not damaged

Power Supply to Sensor (Code 9.3, SID 211/232, SPN 1079/1080)

Cause Reaction Remedy
• Shortcut • Faulty values in oil pressure • Check that the cable harness
and boost pressure sensors to oil pressure and boost
• Fault in sensor
pressure sensor has not been
• Fault code for oil pressure-
damaged
and boost pressure sensor
• Check oil pressure and boost
• Low engine output
pressure sensors
• The instrument shows zero oil
pressure and boost pressure

7748542 10-2009 53
Control System Installation, Fault Code Register

Data Set Memory EEPROM, CIU (Code 9.8, SID 253/SPN 630)
Cause Reaction Remedy
• Internal fault in control mod- • Engine does not start • Re-program the control mod-
ule ule.
• Programming faulty

Fault in Control Unit, CIU (Code 9.8, SID 254/SPN 629)

Cause Reaction Remedy
• Faulty EEPROM, CIU • CIU returns to factory setting • Re- program the unit
• Faulty flash memory, CIU • Engine goes to idle
• Fault in control module, CIU • Engine can not be started

Memory Fault EMS (Code 9.9, SID 240/SPN 628)

Cause Reaction Remedy
• Memory fault in engine man- • Engine might not start • Re-program the unit
agement system

Data Set Memory EEPROM, EMS (Code 9.9, SID 253/SPN 630)
Cause Reaction Remedy
• Internal fault in control mod- • Engine does not start • Re-program the control mod-
ule ule. If the fault remains,
change the control module
• Internal fault in control mod-
ule

Control Module EMS (Code 9.9, SID 254/SPN 629)

Cause Reaction Remedy
• Internal fault in control mod- • Engine misfires • Change engine control unit
ule
• Engine does not start

Wastegate (SID 32/SPN 1188)

Cause Reaction Remedy
• Short circuit to positive (+) or • Warning lamp lights up • Check that the wastegate
negative (-) connector is properly
• Engine control unit limits
mounted
• Open circuit engine power
• Check that the wiring to the
• Wastegate damaged
wastegate is not damaged
mechanically
• Check that the wastegate is
correctly mounted
• Check the wastegate

Fan, rpm sensor (PID 26/SPN 975)

Cause Reaction Remedy
• Open circuit • Warning lamp lights up • Check that the fan actuator is
properly mounted
• Check that the wiring to the
fan actuator is not damaged
• Check that the fan actuator is
correctly mounted
• Check the fan actuator

54 7748542 10-2009
 Control System Installation, Fault Code Register

Fan actuator (SID 33/SPN 975)

Cause Reaction Remedy
• Short circuit to positive (+) or • Warning lamp lights up • Check that the fan actuator is
negative (-) properly mounted
• Open circuit • Check that the wiring to the
fan actuator is not damaged
• Fan actuator damaged
mechanically • Check that the fan actuator is
correctly mounted
• Check the fan actuator

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

7748542 10-2009 57
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Teknisk Information
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7748542 English 10-2009