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Workshop Manual: Group 30 Electrical System E
Workshop Manual: Group 30 Electrical System E
General Information
00-0 General ............................................................................................. 2
Specifications
03-3 Specifications, Electrical ................................................................ 5
Switches and Senders ......................................................................... 5
Engine Protection Map ........................................................................ 9
Special tools
08-2 Special Service Tools ................................................................... 30
Miscellaneous
39-0 General ......................................................................................... 197
Index ......................................................................................................... 201
References to Service Bulletins ............................................................ 203
IMPORTANT!
Neglected or poorly-performed care/service and the
use of spare parts not approved by Volvo Penta, will
mean that AB Volvo Penta no longer guarantees that
the engine conforms to the certified model.
Repair instructions
Introduction Our Mutual Responsibility
The working methods described in this manual are Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the
mounted in a workholding fixture. Maintenance work technical specification may dramatically increase the
is often carried out in situ, in which case - if nothing environmental impact of an otherwise reliable
else is indicated - using the same working methods system. It is therefore critical that the stated wear
as the workshop. tolerances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and
For significance, refer to Safety Information. maintenance schedule must be followed.
Some systems, e.g. fuel systems, often require
DANGER! special expertise and test equipment. A number of
components are factory-sealed, for among other
WARNING! things environmental reasons. Warranty-sealed
components may not be worked on without
CAUTION! authorization to perform such work.
IMPORTANT!, NOTE! Remember that most chemical products, incorrectly
are by no means comprehensive since not everything used, are harmful to the environment. Volvo Penta
can be foreseen as service work is carried out in the recommends the use of biodegradable degreasers
most varied of circumstances. We call attention to whenever components are cleaned, unless otherwise
risks that may occur due to incorrect handling during specified in the Service Manual. When working
work in a well-equipped workshop using working outdoors, take especial care to ensure that oils and
methods and tools tried and tested by us. wash residues etc. are correctly properly for
destruction.
The service manual describes work operations
carried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Tightening torque
Special Tools are designed to ensure the safest and Tightening torques for vital fasteners that must be
most rational working methods possible. It is applied using a torque wrench are indicated in the
therefore the responsibility of anyone using tools or Service Manual, chapter Tightening torques and in
working methods other than those we recommend to the Manual's work descriptions. All torque indications
ensure that no risk of personal injury or mechanical apply to clean threads, bolt heads and mating faces.
damage is present, or that malfunction can result. Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
In some cases, special safety regulations and user
required for fasteners, the correct type will be
instructions may be in force for the tools and
indicated in the job description.
chemicals mentioned in the Service Manual. These
rules must always be observed, so there are no
special instructions about this in the workshop
Torque, angle tightening
manual. When torque/angle tightening, the fastener is
tightened to a specified torque, and tightening then
By following these basic recommendations and using continues through a pre-determined angle.
common sense it is possible to avoid most of the risks
involved in the work. A clean workplace and a clean Example: For 90° angle tightening, the fastener is
product will eliminate many risks of personal injury turned an additional 1/4 turn in one sequence, after
and malfunction. the specified tightening torque has been achieved.
Above all, when working on fuel systems, hydraulic
systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost
importance that dirt and foreign objects are kept
away, as malfunctions or shortened service intervals
may otherwise result.
Combined sensor (D9, D11, D12), oil pressure / oil temperature (engine)
Voltage 5V
Connector 4 pin
Working range, pressure 0–700 kPa (0–7 bar / 0–102 PSI)
Pressure signal 0.5–4.5 V
Working range, temperature -40 °C to +140 °C (-40 °F to +284 °F)
Type Linear/NTC
Max. tightening torque 30 ±5 Nm (22.1 ±3.7 lbf.ft.)
Combined sensor (D9, D11, D12, D16), inlet air pressure / intake manifold temperature
Voltage 5V
Connector 4 pin
Working range, pressure 40–400 kPa (0.4–4 bar / 5.8–58 PSI)
Pressure signal 0.5–4.5 V
Working range, temperature -40 °C to +125 °C (-40 °F to +257 °F)
Type Linear/NTC
Wastegate valve
Operational voltage 20–32 V
Connector 2 pin
Working range, pressure 0–300 kPa (0-3 bar / 0-43.5 PSI)
Pressure signal 0.5–4.5 V
Working range, temperature -30 °C to +130 °C (-22 °F to +266 °F)
Coil resistance 90 ± 4.5 Ω at 20 °C (68 °F)
Alternator
Voltage 14 / 28 V
Connector 2 pin
Capacity 115 A at 14 V / 80 A at 28 V
Starter motor
Voltage 12 / 24 V
Connector 2 pin
Capacity (applies to D9) 5.5 kW at 12/24 V
Capacity (applies to D11) 5.5 kW at 24 V
Capacity (applies to D12, D13) 6.0 kW at 24 V
Capacity (applies to D16) 7.0 kW at 24 V
D9 Propulsion
Sensors Switches
Control and monitoring system Engine Shutdown
System
Sensors Signal Range Warning Warning Derating Shutd. Shutdow
Initial Delay / level level Initial n level
Warning Delay / (Toleranc
Delay Shutd. e)
Delay
Air inlet 0.5-4.5 50-400 kPa 30 sec from 325 kPa (425 335 kPa NA NA
pressure V (7-58 psi) start / 3 sec kPa absolute) (49 psi)
(47 psi (62 psi 50%
abs.)) derating.
Intake manifold 50-0 Ω -40 - 130 °C 90 sec from 80 °C 90 °C NA NA
temperature ±4% start / 2 sec (176 °F) (194 °F)
(-40 - 266 °F Soft
±4%) derate.
Coolant level Digital ON/OFF 30 sec from Low (On / NA NA NA
switch start / 10 sec Closed)
Coolant 50-0 Ω -40 - 140 °C 30 sec from 98 °C 101 °C 1 sec 105 ±2 °C
temperature ±1.5% start / 3 sec (208.4 °F) (213.8 °F) SDU Ch.
(-40 - 284 °F Soft S1
±1.5%) derate. (221 ±3.6
°F SDU
Ch. S1)
Crankcase NA NA NA Rapid 75% NA NA
pressure pressure derating,
increase 100 rpm
Engine speed, Freque - Instant Lost signal NA NA NA
camshaft ncy
Engine speed, Freque - Instant Lost signal NA NA NA
crankshaft ncy
Eng. overspeed Freque 54 puls./rev. Instant Lost signal NA Instant 2070 /
SDU 1800+15% ncy 1863 Hz
(-1 to 0%)
Eng. overspeed Freque 54 puls./rev. Instant Lost signal NA Instant 2530 /
SDU 2200+15% ncy 2277 Hz
(-1 to 0%)
Exhaust gas PT200 0-850 °C 30 sec from 600 °C 620 °C NA NA
temperature ±2.5% start / 1.5 sec (1112 °F) (1148 °F)
after turbine (0-1562 °F Soft
±2.5%) derate.
Oil level sensor Digital ON/OFF 30 sec from Low level NA NA NA
start / 5 sec
Sensors Switches
Control and monitoring system Engine Shutdown
System
Sensors Signal Range Warning Warning Derating Shutd. Shutdow
Initial Delay / level level Initial n level
Warning Delay / (Toleranc
Delay Shutd. e)
Delay
Oil temperature 50-0 Ω -40 - 140 °C 30 sec from 125 °C 128 °C NA NA
(-40 - 284 °F start / 2 sec (257 °F) (262.4 °F)
Soft
derate.
Piston cooling Digital ON/OFF Instant after 120 ±20 kPa 120 kPa NA NA
switch 1000 rpm (17.4 ±2.9 psi) (17.4 psi)
70%
derating
(20% per
sec)
Water in fuel Digital ON/OFF Always Water in fuel NA NA NA
switch
D9 Propulsion
Sensors (rpm Signal Range Initial Delay / Warning Level / Derating Level / Switches
dependent) Delay Shutdown Level Shutdown
Rpm map, kPa (psi) System
Coolant 0.5-4.5 0-300 kPa - 0 rpm 500 1000 1800 2200 -
Pressure V ±3% rpm rpm rpm rpm
(0-43.5 psi
±3%)
Warning level - - 30 sec from 0 0 20 50 70 -
start / 2 sec (2.9) (7.3) (10.2)
Derating level - - 10% trq. 0 0 10 40 60 -
decr./sec (1.5) (5.8) (8.7)
Differential oil NA NA - 0 rpm 500 1000 1500 1800 -
pressure rpm rpm rpm rpm
Warning level - - NA NA NA NA NA NA -
Derating level - - NA NA NA NA NA NA -
Fuel pressure 0.5-4.5 0-700 kPa - 0 rpm 600 1000 1800 2200 -
V ±1.5% rpm rpm rpm rpm
(0-102 psi
±1.5%)
Warning level - - 30 sec from 100 100 150 250 250 -
start / 5 sec (14.5) (14.5) (21.8) (36.3) (36.3)
Derating level - - NA NA NA NA NA NA -
Sensors (rpm Signal Range Initial Delay / Warning Level / Derating Level / Switches
dependent) Delay Shutdown Level Shutdown
Rpm map, kPa (psi) System
Oil pressure 0.5-4.5 0-700 kPa - 0 rpm 500 1000 1800 2300 -
V ±1.5% rpm rpm rpm rpm
(0-102 psi
±1.5%)
Warning level - - 30 sec from -100 170 200 225 250 -
start / 1 sec (-14.5) (24.7) (29.0) (32.6) (36.3)
Derating level - - 10% trq. -120 150 180 205 205 -
decr./sec (-17.4) (21.8) (26.1) (29.7) (29.7)
Shutdown Digital ON/OFF 11 sec ±20% NA NA 120 120 120 Shutdown
level from start / 1 +20 +20 +20 Unit Setting
(Shutd. Unit sec (17.4 (17.4 (17.4 Run detect.
Ch. S3) +2.9) +2.9) +2.9) S2, S3: 510
rpm ±2%
459 Hz ±2%,
54 puls./rev.
Seawater 0.5-4.5 0-300 kPa - 0 rpm 600 1400 1700 1900 -
pressure V ±3% rpm rpm rpm rpm
(0-44 psi
±3%)
Warning level - - 30 sec from 0 5 (0.7) 10 15 20 -
start / 2 sec (1.4) (2.2) (2.9)
Derating level - - NA NA NA NA NA NA -
Rev. gear - - - 0 rpm 600 1300 1500 1800 -
pressure rpm rpm rpm rpm
Warning level NA NA NA NA NA NA NA NA -
Derating level NA NA NA NA NA NA NA NA -
Shutdown Digital ON/OFF 11 sec ±20% NA 400 400 400 400 Shutdown
level from start / 1 +20 +20 +20 +20 Unit Setting
(Shutd. Unit sec (58.0 (58.0 (58.0 (58.0 Run detect.
Ch. S2) +2.9) +2.9) +2.9) +2.9) S2, S3: 510
rpm ±2%
459 Hz ±2%,
54 puls./rev.
D9 MG
Sensors Switches
Control and monitoring system Engine Shutdown
System
Sensors Signal Range Warning Warning Derati Shutd. Shutdow
Initial Delay / level ng Initial n level
Warning level Delay / (Toleranc
Delay Shutd. e)
Delay
Air inlet 0.5-4.5 50-400 ±4.2 kPa 30 sec from 325 kPa (425 NA NA NA
pressure V (7-58 ±0.6 psi) start / 3 sec kPa absolute)
(47 psi (62 psi
abs.))
Intake manifold 50-0 Ω -40 - 130 °C ±4% 90 sec from 80 °C NA NA NA
temperature (-40 - 266 °F ±4%) start / 2 sec (176 °F)
Coolant level Digital ON/OFF 30 sec from Low (On / NA NA NA
switch start / 10 sec Closed)
Coolant 50-0 Ω -40 - 140 °C 30 sec from 98 °C NA 1 sec 105 ±2 °C
temperature ±1.5% start / 3 sec (208.4 °F) SDU Ch.
(-40 - 284 °F S1
±1.5%) (221 ±3.6
°F SDU
Ch. S1)
Engine speed, Freque - Instant Lost signal NA NA NA
camshaft ncy
Engine speed, Freque - Instant Lost signal NA NA NA
crankshaft ncy
Eng. overspeed Freque 54 puls./rev. Instant Lost signal NA Instant 1725 /
SDU 1500+15% ncy 1553 Hz
(-1 to 0%)
Eng. overspeed Freque 54 puls./rev. Instant Lost signal NA Instant 2070 /
SDU 1800+15% ncy 1863 Hz
(-1 to 0%)
Exhaust gas PT200 0-850 °C ±2.5% 30 sec from 600 °C NA NA NA
temperature (0-1562 °F ±2.5%) start / 1.5 sec (1112 °F)
after turbine
Oil level sensor Digital ON/OFF 30 sec from Low level NA NA NA
start / 5 sec
Oil temperature 50-0 Ω -40 - 140 °C 30 sec from 125 °C NA NA NA
(-40 - 284 °F start / 2 sec (257 °F)
Piston cooling Digital ON/OFF Instant after 120 ±20 kPa NA NA NA
switch 1000 rpm (17.4 ±2.9 psi)
Water in fuel Digital ON/OFF Always Water in fuel NA NA NA
switch
D9 MG
Sensors (rpm Signal Range Initial Delay / Warning Level / Derating Level / Switches
dependent) Delay Shutdown Level Shutdown
Rpm map, kPa (psi) System
Coolant 0.5-4.5 0-300 kPa - 0 rpm 500 1000 1500 1800 -
Pressure V ±3% rpm rpm rpm rpm
(0-43.5 psi
±3%)
Warning level - - 30 sec from 0 0 20 50 70 -
start / 2 sec (2.9) (7.3) (10.2)
Derating level - - NA NA NA NA NA NA -
Differential oil NA NA - 0 rpm 500 1000 1500 1800 -
pressure rpm rpm rpm rpm
Warning level - - NA NA NA NA NA NA -
Derating level - - NA NA NA NA NA NA -
Fuel pressure 0.5-4.5 0-700 kPa - 0 rpm 600 1000 1600 1800 -
V ±1.5% rpm rpm rpm rpm
(0-102 psi
±1.5%)
Warning level - - 30 sec from 0 100 200 300 300 -
start / 5 sec (14.5) (29.0) (43.5) (43.5)
Derating level - - NA NA NA NA NA NA -
Oil pressure 0.5-4.5 0-700 kPa - 0 rpm 500 1000 1800 2300 -
V ±1.5% rpm rpm rpm rpm
(0-102 psi
±1.5%)
Warning level - - 30 sec from 0 160 200 225 250 -
start / 1 sec (23.2) (29.0) (32.6) (36.3)
Derating level - - NA NA NA NA NA NA -
Shutdown Digital ON/OFF 11 sec ±20% NA NA 120 120 120 Shutdown
level from start / 1 +20 +20 +20 Unit Setting
(Shutd. Unit sec (17.4 (17.4 (17.4 Run detect.
Ch. S3) +2.9) +2.9) +2.9) S2, S3: 800
rpm ±2%
720 Hz ±2%,
54 puls./rev.
Seawater 0.5-4.5 0-300 kPa - 0 rpm 600 1400 1700 1900 Only HE and
pressure V ±3% rpm rpm rpm rpm KC
(0-44 psi
±3%)
Warning level - - 30 sec from 0 5 (0.7) 10 15 20 -
start / 2 sec (1.4) (2.2) (2.9)
Derating level - - NA NA NA NA NA NA -
D11 Propulsion
Derate to engine protection map
Parameter “Yellow lamp” “Red lamp” Derating
High coolant temperature 98 °C (208 °F) 101 °C (213.8 °F) 101 °C (213.8 °F) –0%
103 °C (217.4 °F) –25%
106 °C (222.8 °F) –50%
High oil temperature 120 °C (248 °F) 122 °C (251.6 °F) 122 °C (251.6 °F) –0%
124 °C (255.2 °F) –50%
126° (258.8 °F) –70%
High intake manifold 75 °C (167 °F) 80 °C (176 °F) 80 °C (176 °F) –0%
temperature 85 °C (185 °F) –50%
90 °C (194 °F) –70%
High air inlet pressure 270 kPa (39.2 PSI) 280 kPa (40.6 PSI) >280 kPa (40.6 PSI) –50%
Low coolant level Switch - -
Crankcase pressure
Red lamp and max. 1200 rpm and 75% derate.
D12 Propulsion
Sensors Warning / Alarm level Derating level Condition/delay Derating
Alarm
Intake manifold 80 °C (176 °F) 85 °C (185 °F) - Soft derate
temperature
Coolant 95 °C (203 °F) 98 °C (208.4 °F) - -
temperature
Crankcase Rapid pressure - - 1000 rpm
pressure increase
Oil temperature 125°C (257 °) 128°C (262,4 °F) - -
128°C (262.4 °F)
Piston cooling 150 ±20 kPa (21.8 150 ±20 kPa (21.8 Above 1300 rpm Yes, 70%
pressure ±2.9 PSI) ±2.9 PSI) instant
Water in fuel Water in fuel - - -
Air inlet pressure 1700 rpm 1900 rpm 2100 rpm 2300 rpm 2360 rpm -
Alarm level 450 kPa 440 kPa 430 kPa 395 kPa 390 kPa -
(65.3 PSI) (63.8 PSI) (62.4 PSI) (57.3 PSI) (56.6 PSI)
Derating limit 460 kPa 450 kPa 440 kPa 405 kPa 400 kPa Yes, 50%
(66.7 PSI) (65.3 PSI) (63.8 PSI) (58.7 PSI) (58.0 PSI)
Fuel pressure 500 rpm 1800 rpm 2300 rpm - - -
Alarm level 50 kPa 200 kPa 200 kPa - - -
(7.3 PSI) (29.0 PSI) (29.0 PSI)
Oil pressure 500 rpm 1000 rpm 1800 rpm 2300 rpm - -
Alarm level 150 kPa 200 kPa 225 kPa 250 kPa - -
(21.8 PSI) (29.0 PSI) (32.6 PSI) (36.3 PSI)
Derating limit 130 kPa 170 kPa 205 kPa 230 kPa - Yes, 70%
(18.9 PSI) (24.7 PSI) (29.7 PSI) (33.4 PSI)
D13 Propulsion
D13 Propulsion
Air inlet pressure 600 rpm 1000 rpm 1500 rpm 2000 rpm 2300 rpm
(D13B-C/G R4 800 hp)
Warning level 420 kPa 420 kPa 420 kPa 420 kPa 420 kPa -
0 % load (60.9 PSI) (60.9 PSI) (60.9 PSI) (60.9 PSI) (60.9 PSI)
Warning level 420 kPa 268 kPa 295 kPa 333 kPa 345 kPa -
100 % load (60.9 PSI) (38.9 PSI) (42.8 PSI) (48.3 PSI) (50.0 PSI)
Derating level 430 kPa 278 kPa 305 kPa 343 kPa 355 kPa 50% diff. between
100 % load (62.4 PSI) (40.3 PSI) (44.2 PSI) (49.7 PSI) (51.5 PSI) max torque and
engine prot. map
Air inlet pressure 600 rpm 1000 rpm 1500 rpm 2000 rpm 2300 rpm
(D13B-G R5 900 hp)
Warning level 420 kPa 420 kPa 420 kPa 420 kPa 420 kPa -
0 % load (60.9 PSI) (60.9 PSI) (60.9 PSI) (60.9 PSI) (60.9 PSI)
Warning level 420 kPa 322 kPa 335 kPa 356 kPa 366 kPa -
100 % load (60.9 PSI) (611.6 (635.0 (672.8 (690.8
PSI) PSI) PSI) PSI)
Derating level 430 kPa 332 kPa 345 kPa 366 kPa 376 kPa 50% diff. between
100 % load (62.4 PSI) (629.6 (653 PSI) (690.8 (708.8 max torque and
PSI) PSI) PSI) engine prot. map
Air inlet pressure 600 rpm 1000 rpm 1500 rpm 2000 rpm 2300 rpm
(D13B-D R3 700hp)
Warning level 305 kPa 305 kPa 305 kPa 295 kPa 259 kPa -
(44.2 PSI) (44.2 PSI) (44.2 PSI) (42.8 PSI) (37.6 PSI)
Derating level 315 kPa 315 kPa 315 kPa 305 kPa 269 kPa 50% diff. between
(45.7 PSI) (45.7 PSI) (45.7 PSI) (44.2 PSI) (39.0 PSI) max torque and
engine prot. map
Intake manifold 600 rpm 1000 rpm 1500 rpm 2000 rpm 2300 rpm
temperature
(D13B-C/G)
Warning level 80 °C (176 80 °C (176 80 °C (176 65 °C (149 65 °C (149 -
°F) °F) °F) °F) °F)
Derating level 85 °C (185 85 °C (185 85 °C (185 70 °C (158 70 °C (158 See soft derate 4
°F) °F) °F) °F) °F)
Fuel pressure 600 rpm 1000 rpm 1200 rpm 1400 rpm 2300 rpm
Warning level 180 kPa 240 kPa 255 kPa 270 kPa 270 kPa -
(26.1 PSI) (34.8 PSI) (37.0 PSI) (39.2 PSI) (39.2 PSI)
Oil pressure 500 rpm 1000 rpm 1500 rpm 2300 rpm
(D13B-C/G)
Warning level 120 kPa 200 kPa 265 kPa 265 kPa -
(17.4 PSI) (29.0 PSI) (38.4 PSI) (38.4 PSI)
Derating level 90 kPa 170 kPa 235 kPa 235 kPa -
(13.1 PSI) (24.7 PSI) (34.1 PSI) (34.1 PSI)
Shutdown level (Shutdown N/A N/A 150 ±20 150 ±20 150 ±20 Shutdown Unit
Unit Channel S3) kPa (21.8 kPa (21.8 kPa (21.8 Setting
±2.9 PSI) ±2.9 PSI) ±2.9 PSI) S2, S3: 510 rpm
±2%
1300 Hz ±2%
153 pulses / rev.
Oil pressure 0 rpm 600 rpm 1000 rpm 1500 rpm 2300 rpm
(D13B-D)
Warning level -100 kPa 120 kPa 200 kPa 265 kPa 265 kPa -
(-14.5 PSI) (17.4 PSI) (29.0 PSI) (38.4 PSI) (38.4 PSI)
Derating level -130 kPa 90 kPa 170 kPa 235 kPa 235 kPa -
(-18.9 PSI) (13.1 PSI) (24.7 PSI) (34.1 PSI) (34.1 PSI)
Shutdown level (Shutdown N/A N/A 150 ±20 150 ±20 150 ±20 Shutdown Unit
Unit Channel S3) kPa (21.8 kPa (21.8 kPa (21.8 Setting
±2.9 PSI) ±2.9 PSI) ±2.9 PSI) S2, S3: 510 rpm
±2%
1300 Hz ±2%
153 pulses / rev.
Coolant pressure 0 rpm 600 rpm 1000 rpm 1500 rpm 2300 rpm
(D13B-C/D)
Warning level 0 kPa (0.0 5 kPa (0.7 30 kPa 55 kPa 125 kPa -
PSI) PSI) (4.4 PSI) (8.0 PSI) (18.1 PSI)
Derating level -10 kPa -5 kPa 20 kPa 45 kPa 115 kPa -
(-1.5 PSI) (-0.7 PSI) (2.9 PSI) (6.5 PSI) (16.7 PSI)
Seawater pressure 600 rpm 1000 rpm 1500 rpm 1900 rpm 2300 rpm
(D13B-C/D)
Warning level 5 kPa (0.7 20 kPa 40 kPa 60 kPa 60 kPa -
PSI) (2.9 PSI) (5.8 PSI) (8.7 PSI) (8.7 PSI)
Derating level -5 kPa 10 kPa 30 kPa 50 kPa 50 kPa -
(-0.7 PSI) (1.5 PSI) (4.4 PSI) (7.3 PSI) (7.3 PSI)
D16 Propulsion
Sensors Switches
Control and monitoring system Engine Shutdown
System
Sensors Signal Range Warning Warning Derating Shutd. Shutdo
Initial Delay / level level Initial wn level
Warning Delay / (Toleran
Delay Shutd. ce)
Delay
Air inlet 0.5-4.5 50-400 kPa 30 sec from 300 kPa (400 310 kPa (45 NA NA
pressure V (7-58 psi) start / 2.25 sec kPa absolute) psi)
(44 psi (58 psi 50% derating.
abs.))
Air inlet 50-0 Ω -40 - 130 °C 90 sec from 80 °C 90 °C NA NA
pressure ±4% start / 2.25 sec (176 °F) (194 °F)
after turbine (-40 - 266 °F See soft
±4%) derate 3.
Coolant level Digital ON/OFF 30 sec from Low (On / NA NA NA
switch start / 7.5 sec Closed)
Coolant 50-0 Ω -40 - 140 °C 30 sec from 98 °C 101°C 1 sec 105 ±2
temperature ±1.5% start / 2.25 sec (208.4 °F) (213.8 °F) °C SDU
(-40 - 284 °F See soft Ch. S1
±1.5%) derate 1. (221 ±3.6
°F SDU
Ch. S1)
Engine Freque - Instant Lost signal NA NA NA
speed, ncy
camshaft
Engine Freque - Instant Lost signal NA NA NA
speed, ncy
crankshaft
Eng. Freque 153 puls./rev. Instant Lost signal NA Instant 2070 /
overspeed ncy 5279 Hz
SDU (-1 to
1800+15% 0%)
Eng. Freque 153 puls./rev. Instant Lost signal NA Instant 2185 /
overspeed ncy 5572 Hz
SDU (-1 to
1900+15% 0%)
Exhaust PT200 0-850 °C 30 sec from 650 °C 665 °C NA NA
Temperature (0-1562 °F) start / 1 sec (1202 °F) (1229 °F)
See soft
derate 4.
Oil level Digital ON/OFF 30 sec from Low level NA NA NA
sensor start / 5 sec
Sensors Switches
Control and monitoring system Engine Shutdown
System
Sensors Signal Range Warning Warning Derating Shutd. Shutdo
Initial Delay / level level Initial wn level
Warning Delay / (Toleran
Delay Shutd. ce)
Delay
Oil 50-0 Ω -40 - 140 °C 30 sec from 125 °C 128 °C NA NA
temperature (-40 - 284 °F start / 1.5 sec (257 °F) (262.4 °F)
See soft
derate 2.
Piston Digital ON/OFF 30 sec from 120 ±20 kPa 120 kPa NA NA
cooling start / 4 sec (17.4 ±2.9 psi) (17.4 psi)
switch 70% derating.
Rev. gear NA NA NA NA NA NA NA
temperature
Water in fuel Digital ON/OFF Always Water in fuel NA NA NA
switch
D16 Propulsion
Sensors (rpm Signal Range Initial Delay / Warning Level / Derating Level / Switches
dependent) Delay Shutdown Level Shutdown
Rpm map, kPa (psi) System
Coolant 0.5-4.5 0-300 kPa - 0 rpm 600 1000 1500 1800 -
Pressure V ±3% rpm rpm rpm rpm
(0-43.5 psi
±3%)
Warning level - - 30 sec from 0 5 (0.7) 55 100 130 -
start / 1.5 sec (8.0) (14.5) (18.9)
Derating level - - 10% trq. -50 -45 5 (0.7) 50 80 -
(50% decr./sec (-7.3) (-6.5) (7.3) (11.6)
remaining trq.)
Shutd. Level Digital ON/OFF 11 sec ±20% NA NA NA NA NA Shutdown
(Shutd. Unit from start / 1 Unit Setting
Ch. S4) sec S4: 510 rpm
±2%
1300 Hz ±2%,
153 puls./rev.
Differential oil NA NA - 0 rpm 500 1000 1500 1800 -
pressure rpm rpm rpm rpm
Warning level - - NA NA NA NA NA NA -
Derating level - - NA NA NA NA NA NA -
Fuel pressure 0.5-4.5 0-700 kPa - 0 rpm 500 1000 1800 1900 -
V (0-102 psi) rpm rpm rpm rpm
Warning level - - 30 sec from -50 50 75 200 200 -
start / 10 sec (-7.3) (7.3) (10.9) (29.0) (29.0)
Derating level - - NA NA NA NA NA NA -
Sensors (rpm Signal Range Initial Delay / Warning Level / Derating Level / Switches
dependent) Delay Shutdown Level Shutdown
Rpm map, kPa (psi) System
Oil pressure 0.5-4.5 0-700 kPa - 0 rpm 500 1000 1500 1900 -
V (0-102 psi) rpm rpm rpm rpm
Warning level - - 30 sec from -100 160 200 250 250 -
start / 0.75 sec (-14.5) (23.2) (29.0) (36.3) (36.3)
Derating level - - 10% trq. -10 140 180 230 230 -
(30% decr./sec (-1.5) (20.3) (26.1) (33.4) (33.4)
remaining trq.)
Shutd. Level Digital ON/OFF 11 sec ±20% NA NA NA NA NA Shutdown
(Shutd. Unit from start / 1 Unit Setting
Ch. S4) sec S4: 510 rpm
±2%
1300 Hz ±2%,
153 puls./rev.
Seawater 0.5-4.5 0-300 kPa - 0 rpm 600 1400 1700 1900 Only HE and
pressure V (0-44 psi) rpm rpm rpm rpm KC
Warning level - - 30 sec from -20 5 (0.7) 25 35 40 Only HE and
start / 4 sec (-2.9) (3.6) (5.1) (5.8) KC
Derating level - - NA NA NA NA NA NA -
Rev. gear - - - 0 rpm 600 1000 1500 1800 -
pressure rpm rpm rpm rpm
Warning level NA NA NA NA NA NA NA NA -
Derating level NA NA NA NA NA NA NA NA -
Shutd. Level Digital ON/OFF 4 sec from NA 400 400 400 400 Shutdown
(Shutd. Unit start / 1 sec ±20 ±20 ±20 ±20 Unit Setting
Ch. S2) (58 (58 (58 (58 S2, S3: 510
±2.9) ±2.9) ±2.9) ±2.9) rpm ±2%
1300 Hz ±2%,
153 puls./rev.
D16
1) Soft derate, Speed 101 °C (213.8 °F) 103 °C (217.4 °F) 106 °C (222.8 °F)
coolant temp
Remaining torque 600 rpm 100% 100% 100%
1200 rpm 100% 91% 82%
1800 rpm 100% 83% 66%
2) Soft derate, oil Speed 128 °C (262.4 °F) 130 °C (266 °F) 135 °C (275 °F)
temp
Remaining torque 600 rpm 100% 100% 100%
1200 rpm 100% 91% 74%
1800 rpm 100% 83% 52%
3) Soft derate, Speed 90 °C (194 °F) 95 °C (203 °F) 105 °C (221 °F)
intake manifold
temp.
Remaining torque 600 rpm 100% 100% 100%
1200 rpm 100% 82% 74%
1800 rpm 100% 66% 52%
4) Soft derate, Speed 665 °C (1229 °F) 675°C (1247 °F) 680°C (1256 °F) 685°C (1265 °F)
exhaust temp
Remaining torque 600 rpm 100% 100% 100% 100%
1200 rpm 100% 96% 93% 89%
1800 rpm 100% 93% 86% 80%
D16 MG
Sensors Switches
Control and monitoring system Engine Shutdown
System
Sensors Signal Range Warning Initial Warning Deratin Shutd. Shutdo
Delay / Warning level g level Initial wn level
Delay Delay / (Toleran
Shutd. ce)
Delay
Air inlet 0.5-4.5 50-400 kPa 30 sec from start / 300 kPa (400 NA NA NA
pressure V (7-58 psi) 2.25 sec kPa absolute)
(44 psi (58 psi
abs.))
Air inlet 50-0 Ω -40 - 130 °C 90 sec from start / 80 °C NA NA NA
pressure after ±4% 2.25 sec (176 °F)
turbine (-40 - 266 °F
±4%)
Coolant level Digital ON/OFF 30 sec from start / Low (On / NA NA NA
switch 7.5 sec Closed)
Coolant 50-0 Ω -40 - 140 °C 30 sec from start / 98 °C NA 1 sec 105 ±2
temperature ±1.5% 2.25 sec (208.4 °F) °C SDU
(-40 - 284 °F Ch. S1
±1.5%) 221 ±3.6
°F SDU
Ch. S1
Engine speed, Freque - Instant Lost signal NA NA NA
camshaft ncy
Engine speed, Freque - Instant Lost signal NA NA NA
crankshaft ncy
Eng. overspeed Freque 153 puls./rev. Instant Lost signal NA Instant 1725 /
SDU 1500+15% ncy 4399 Hz
(-1 to
0%)
Eng. overspeed Freque 153 puls./rev. Instant Lost signal NA Instant 2070 /
SDU 1800+15% ncy 5279 Hz
(-1 to
0%)
Exhaust PT200 0-850 °C 30 sec from start / 650 °C NA NA NA
Temperature (0-1562 °F) 5 sec (1202 °F)
Oil level sensor Digital ON/OFF 30 sec from start / Low level NA NA NA
5 sec
Oil temperature 50-0 Ω -40 - 140 °C 30 sec from start / 125 °C NA NA NA
(-40 - 284 °F 2.25 sec (257 °F)
Piston cooling Digital ON/OFF 20 sec from start / 120 ±20 kPa NA NA NA
switch 2.25 sec (17.4 ±2.9 psi)
Water in fuel Digital ON/OFF NA Water in fuel NA NA NA
switch
D16 MG
Sensors (rpm Signal Range Initial Delay / Warning Level / Derating Level / Switches
dependent) Delay Shutdown Level Shutdown
Rpm map, kPa (psi) System
Coolant 0.5-4.5 0-300 kPa - 0 rpm 500 1000 1500 1800 -
Pressure V ±3% rpm rpm rpm rpm
(0-43.5 psi
±3%)
Derating level - - NA NA NA NA NA NA -
Shutd. Level Digital ON/OFF 11 sec ±20% NA NA NA NA NA Shutdown
(Shutd. Unit from start / 1 Unit Setting
Ch. S4) sec S4: 800 rpm
±2%
2040 Hz ±2%,
153 puls./rev.
Differential oil NA NA - 0 rpm 500 1000 1500 1800 -
pressure rpm rpm rpm rpm
Warning level - - NA NA NA NA NA NA -
Derating level - - NA NA NA NA NA NA -
Fuel pressure 0.5-4.5 0-700 kPa - 0 rpm 600 1000 1500 1800 -
V (0-102 psi) rpm rpm rpm rpm
Warning level - - 30 sec from -50 50 75 175 200 -
start / 5 sec (-7.3) (7.3) (10.9) (25.4) (29.0)
Derating level - - NA NA NA NA NA NA -
Oil pressure 0.5-4.5 0-700 kPa - 0 rpm 500 1000 1500 1900 -
V (0-102 psi) rpm rpm rpm rpm
Warning level - - 30 sec from -100 150 250 250 250 -
start / 2.25 sec (-14.5) (21.8) (36.3) (36.3) (36.3)
Derating level - - NA NA NA NA NA NA -
Shutd. Level Digital ON/OFF 11 sec ±20% NA NA NA NA NA Shutdown
(Shutd. Unit from start / 1 Unit Setting
Ch. S4) sec S4: 800 rpm
±2%
2040 Hz ±2%,
153 puls./rev.
Seawater 0.5-4.5 0-300 kPa - 0 rpm 600 1400 1700 1900 Only HE and
pressure V (0-44 psi) rpm rpm rpm rpm KC
Warning level - - 30 sec from -20 5 (0.7) 25 35 40 Only HE and
start / 3.75 sec (-2.9) (3.6) (5.1) (5.8) KC
Derating level - - NA NA NA NA NA NA -
Read the safety information below and the service manual section About this Workshop manual and Repair
instructions carefully before repair and service work is begun.
!
This symbol is used in the service 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 manual have the following order of priority:
DANGER!
Indicates a hazardous situation, which, if not avoided, 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!
Is used to draw your attention to something that may cause minor damage or a minor malfunction to the product
or property.
NOTICE! Is used to draw your attention to important information that will facilitate the work or operation in
progress.
This symbol is used to inform that added information needs to be read. And where to find needed information.
This symbol is used where VODIA computer is needed,. either for fault tracing, testing or for programming.
A compilation of safety precautions that must be taken and risks which must be paid attention to is
presented in the following pages.
Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply to the engine at the main switch ! engine is hot. Steam or hot coolant can spray
(switches) and lock it (them) in the off position out and system pressure will be lost. Open the
before starting work. Post a warning notice at filler cap slowly, and release the pressure in the
the main circuit breaker. cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed when the engine is hot.
As a rule, all service operations must be carried Hot oil can cause burns. Avoid skin contact with
! out with the engine stopped. However, some ! hot oil. Ensure that the lubrication system is not
work, such as adjustments, will require the under pressure before any work is begun.
engine to be running. Approaching an engine Never start or operate the engine with the oil
which is running is a safety risk. Bear in mind filler cap removed, because of the risk of oil
that loose clothing or long hair can fasten in ejection.
rotating parts and cause serious personal
injury.
Be aware of hot surfaces (exhaust pipes, Never start the engine without installing the air
! turbos, charge air pipes, starting heaters etc.) ! filter. The rotating compressor turbine in the
and hot fluids in pipes and hoses on an engine turbocharger can cause severe injury. Foreign
that is running or has just stopped. objects entering the intake ducts can also cause
If work is done adjacent to a running engine, a mechanical damage. Install all protective
careless movement or a dropped tool may in the covers before the engine is started.
worst case lead to personal injury.
Ensure that the warning symbols or information Only start the engine in a well-ventilated space.
! decals on the product are always clearly visible. ! When running in a confined space, exhaust
Replace decals which have been damaged or fumes and crankcase gases must be led away
painted over. from the engine bay or workshop area.
Avoid getting oil on your skin! Protracted or The majority of chemicals e.g. engine and
! repeated exposure to oil can cause skin to ! transmission oils, glycol, gasoline, and diesel
become dry. Irritation, dryness, eczema and oil, together with chemicals for workshop use
other skin problems may then result. From a such as degreasing agents, paints and
health standpoint, used oil is more dangerous solvents, are injurious to health. Carefully read
than new. Use protective gloves and avoid oil- the instructions on the product packaging!
soaked clothes and rags. Wash regularly, Always follow a product's safety directions, e.g.
especially before eating. Use suitable barrier use of protective mask, glasses, gloves etc.
creams to counteract drying out of the skin and Ensure that other personnel are not exposed to
to aid dirt removal. substances that are injurious to health. Ensure
good ventilation. Handle used and leftover
chemicals in the prescribed manner.
Stop the engine and turn off the electrical supply Clutch adjustments must be carried out with the
! at the main switch(es) before carrying out work ! engine stopped.
on the electrical system.
Always use protective glasses or goggles when Never start the engine with the valve cover
! carrying out work where a risk of splinters, ! removed. There is a risk of personal injury.
grinding sparks, splashes from acid or other
chemicals is present. Your eyes are extremely
sensitive; injury may cause blindness!
Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. Marine engines: Close the sea cock / cooling
water inlet valve before work on the cooling
system is begun.
All fuels, as well as many chemicals, are Make sure that oil, fuel-soaked rags, and used
! flammable. Do not allow open flames or sparks ! fuel and oil filters are stored in a safe manner.
in their vicinity. Gasoline, some thinners, and Rags soaked in oil can spontaneously ignite
hydrogen gas from batteries are extremely under certain circumstances. Used fuel and oil
flammable and explosive when mixed with air in filters are environmentally hazardous waste
the correct proportions. No Smoking! Ensure and must be handed to an approved waste
that the work area is well ventilated and take the management facility for destruction, as must
necessary safety precautions before welding or any used lubrication oil, contaminated fuel,
grinding work is begun. Always ensure that paint residue, solvents, degreasers and wash
there are fire extinguishers close at hand in the residue.
work area.
Batteries must never be exposed to open Never work alone when removing heavy
! flames or electric sparks. Never smoke in the ! components, even when using lifting devices
vicinity of the batteries; they generate hydrogen such as locking tackle lifts. When using a lifting
gas when charged, which is explosive when device, two people are usually required to do
mixed with air. This gas is easily ignited and the work - one to take care of the lifting device
highly explosive. A spark, which can be caused and the other to ensure that components are
by incorrect battery connection, is sufficient to lifted clear and not damaged during the lifting
cause a battery to explode and cause damage. operations.
Never transpose the positive (+) and negative The existing lugs on the engine should be used
! (-) battery posts when installing batteries. Such ! for lifting. Always check that the lifting
a transposition can result in serious damage to equipment used is in good condition and has the
electrical equipment. Refer to the wiring load capacity to lift the engine (engine weight
diagram. including gearbox or extra equipment). For safe
Always use protective goggles when charging handling and to avoid damaging components
and handling the batteries. Battery electrolyte fitted to the top of the engine, the engine must
contains sulfuric acid which is highly corrosive. be lifted with a correctly adjusted lifting boom.
Should the battery electrolyte come into contact All chains or wires must run parallel to each
with unprotected skin, wash it off immediately other and as perpendicular to the engine as
using soap and copious amounts of water. If you possible. If other equipment attached to the
get battery acid in your eyes, flush at once with engine has altered its center of gravity, special
copious amounts of water and seek medical lifting devices may be needed to obtain the
assistance immediately. correct balance for safe handling. Never
perform any work on an engine that is only
suspended from the lifting equipment.
The components in the electrical and fuel Exercise extreme caution when leak-detecting
! systems on Volvo Penta products are designed ! on the fuel system and testing the fuel injector
and manufactured to minimize the risk of fire nozzles. Use eye protection. The jet from a fuel
and explosion. The engine must not be run in nozzle has very high pressure and great
areas where there are explosive materials. penetration power. Fuel can force its way deep
into body tissue and cause severe injury. There
is a risk of blood poisoning (septicemia).
Only use fuels and lubricating oils Never use a high-pressure washer for cleaning
! recommended by Volvo Penta. Refer to the ! the engine.
Operator's Manual for the product in question. Pay attention to the following when using a high-
Use of fuels that are of a lower grade may pressure washer on components other than the
damage the engine, the injection pump and the actual engine: Never direct the water jet at
injectors. On a diesel engine, low grade fuel can seals, rubber hoses or electrical components.
cause the control rod to bind and the engine to
over-rev, with the risk of engine damage and
personal injury as a result. Low fuel and oil
grades may result in high service, maintenance
and repair costs.
Fuel delivery pipes must not be bent or When working on the engine; perform leakage
! straightened under any circumstances. Cracks ! and function test as necessary.
may occur. Damaged pipes must be replaced.
VODIA
75
8856
5
4
3
2
1
P0008793
p0005128
30-0 General
4 5
3
11
8
9
10
P0007164
12 13
16
15
6
8
5
47700583
9
18
4
1 28
2 28
3 2
2 NWODTUHS 24
RO LS
2 TINU 2
RS 6638183 2
1T ETAD .TCAFUNAM
FS
AS 2
2 612 060 BS
66 2
56 DEEPSREVO SO
2 2
6S .PMET TSUAHXE 21
2 2
5S .PMET LIO .GNE 11
2 2
4S .SSERP TNALOOC 01
2 2
3S .SSERP LIO .GNE 9
10
2 2
2S .SSERP LIO RAEG 8
2 2
1S .PMET TNALOOC 7
REWOP NRG
TESER ERIW NEKORB
MRALA DEEPSREVO DER
VF
4S ROF TCETED NUR WLY
SS 3S,2S ROF TCETED NUR NRG
WIRE
6S
5S 6S
SHUTDOWN
BROKEN
5S
ALARMS
4S
4S
3S 3S
2S !LOOT CITSALP ESU 2S
1S 1S
TSET DEEPSREVO
3
Location of sensors, D9 classified
2
30-0 General
13 14
P0017067
12
11
1
34
30-0 General
P0018112
P0019225
P0019215
Component description
AUX stop button
There are two different kinds of AUX stop buttons.
When the AUX stop button is pressed the power supply
to the engine control unit (EMS2) is switched off and
the engine will shut down.
Non-classified system
The aux stop breaks a circuit from the main relay to the
EMS2.
Classified system
The aux stop breaks two circuits from the power
module to the EMS2.
On D13 engines a circuit will also close which indicates
that the aux stop is pressed.
Starter motor
The starter motor is installed in the flywheel housing,
on the right-hand side of the engine. The starter motor
relay is connected between battery positive and EMS2.
When the relay is to be activated during the starting
sequence EMS2 alter the potential of the output.
The starter motor solenoid is engaged via the starter
relay, which is activated when the starter key is turned
to position III.
P0007169 1 The starter relay (1) is installed on the side of the
starter motor solenoid.
If there is no power module installed, a first-start relay
is also included in the starter motor circuit. This is
located underneath the plastic housing beside the stop
button bracket.
Overheating protection
The starter motor circuit is automatically cut for 30
seconds to protect the starter motor against
overheating. Leave the starter motor to cool for at least
five minutes (if possible) before making a new start
attempt.
Alternator 24 V – 80 A, 12 V – 115 A
The alternator is belt driven and mounted on the front
of the engine, on the left.
P0010639
Unit injector
The unit injectors are installed on the cylinder head,
underneath the valve cover.
The amount of fuel injected and injection duration is
controlled by the control unit, via electromagnetically
controlled fuel valves in the unit injectors. This means
that the engine always receives the correct volume of
fuel in all operating conditions, which offers lower fuel
consumption, minimal exhaust emissions etc.
The unit injectors are made and classified by tolerance.
D11, D13
p0004941
P0008694
Power Module
The Power Module is used on classified installations
with a backup battery.
An electronic relay function on the Power Module
regulates the power supply from the batteries onto the
rest of the system. The Power Module also ensures
that both batteries are connected and monitors the
battery voltage.
7A EasyLink
P0016541
P0016555
P0011560
P0017109
IMPORTANT!
• MCU prop engines emulates PCU (MID 187)
• MCU aux engines emulates DCU (MID 144)
P0017123
P0017124
P0016347
SDU adjustments
P0018657
1 Connect terminal 1 to 24 V and terminal 2 to 0 V. 6 If the green LED (4) is not lit: Turn “A” counter-
clockwise (–), until the green LED is lit. The run
2 Switch on the supply and make sure the green detection limit is now configured.
LED (POWER) is lit on the SDU. Some alarms can
If the green LED is lit: Turn “A” slightly clockwise
be activated, ignore these.
(+) to switch off the LED. Then turn “A” counter-
clockwise (–) until the green LED is lit. The run
3 Connect a sinusoidal frequency generator (G) to detection limit is now configured.
the 65, 66 inputs.
4 Connect 88890074 Multimeter in parallel with the 7 Ramp the frequency from 0 Hz to the run detection
frequency generator to measure the frequency. level to make sure that correct limit is configured.
5 Set the frequency generator to the run detection 8 Make the same procedure for the S4 run detection
frequency. (configure “B”). The S4 LED (3) color is yellow.
P0018658
Overspeed configuration If the red LED is lit: Keep the shutdown reset
Special tool: 88890074 Multimeter button (R) pushed and turn "C" slightly clockwise
Other special equipment: Frequency generator to switch off the LED. Release the shutdown reset
button. Turn "C" counter-clockwise until the red
LED is lit.
1 Connect the sinusoidal frequency generator to the 5 Set the frequency generator to 0 Hz and then push
65, 66 inputs. the shutdown reset button (R).
2 Connect 88890074 Multimeter in parallel with the 6 Ramp the frequency from 0 Hz to the overspeed
frequency generator (G) to measure the limit to make sure that correct limit is configured.
frequency.
7 If the S6 channel is used, proceed with the
3 Set the frequency generator to the overspeed exhaust temperature configuration.
frequency seen in the table on the next page.
8 Enable the channels S1–S6 according to the
4 If the red LED (2) is not lit: Turn “C” counter- engine specification (refer to section “Channel
clockwise until the red LED is lit. set-up”). Fit the SDU cover.
P0018659
O
• Throttle opening
P0007162 N M
• Oil pressure
Engine Control Unit (ECU)
A Engine speed • Oil temperature
B Throttle opening • Crankcase pressure
C Oil pressure/-temperature
• Air inlet pressure / intake manifold temperature
D Air inlet pressure / intake manifold temperature
E Crankcase pressure
• Fuel pressure
F Coolant temperature • Fuel alarm, ”water in fuel”
G Diagnostics
• Camshaft position
H Camshaft position
I Fuel alarm, water in fuel
• Coolant level/oil level
J Fuel pressure • Piston cooling pressure
K Coolant level/oil level
The information provides information about current
L Piston cooling pressure operation conditions and allows the processor to
M Checking the wastegate control (D12) calculate the correct fuel volume, monitor engine
status etc.
N Fuel volume
O Injection advance
Fuel control
The amount of fuel injected into the engine and the
injection advance are fully electronically controlled, via
fuel valves and the unit injectors, once the control unit
has analyzed the engine’s fuel requirements.
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.
Normal start
Both the camshaft sensor and flywheel sensor function
normally. The engine is cranked until the engine
control unit discovers that cylinder 1 is next in line for
injection. Fuel is injected and the engine starts.
Cylinder balancing
During idling, the control unit can provide the cylinders
with different amounts of fuel. This is to give the engine
more even idling. At higher engine speeds, all cylinders
receive the same amount of fuel.
Diagnostic Function
The EMS system has a built-in diagnostic function
which can discover any faults in the engine and
sensors.
The function of the diagnostic function is to discover
and localize any function faults in the EMS system, to
protect the engine and guarantee continued operation
if a serious function fault should occur.
Repair Instructions
General advice on working with EMS engines
The following advice must be followed to avoid damage to the engine control unit and other electronics.
IMPORTANT!
The system must be switched off and the system
current disconnected when any of the connectors on
the engine control unit is connected or disconnected.
• Only batteries may be used for start help. A help
• Never disconnect the current with the main
start device can produce a very high voltage and
switches when an engine is running.
damage the control unit and other electronics.
• Never undo a battery cable when the engine is
• If damage is discovered in a cable harness the
running.
two 36-pin connectors for the enginecontrol unit
• Turn the main switches off or disconnect the and the 8-pin connector between the engine and
battery cables during quick charging of the the EVC system must be disconnected.
batteries.
• If a connector is disconnected from a sensor, be
NOTICE! During normal trickle charging, it is not very careful to avoid allowing the contact pins to
necessary to turn the main switches off. come into contact with oil, water or dirt.
Electrical Welding
IMPORTANT!
Undo all connectors from the engine control unit before
you start electric welding.
IMPORTANT!
Cut the engine current before the control unit
connector is disconnected.
IMPORTANT!
After welding is completed, the disconnected
components, such as alternator cables and battery
cables must be connected in the correct order.
• Look for oxidation, which can impair contact in Wear can also cause faults. For this reason, avoid
connectors. disconnecting a connector unless it is necessary.
• Check that terminals are undamaged, that they Other contact problems can be caused by damage to
are correctly inserted into their connectors, and pins, sockets and connectors etc.
that the cable is correctly terminated in the
terminal. Shake cables and pull connectors during
measurement, to find where the cable is damaged.
• Check that there is good mechanical contact in
the connector. Use a loose pin to check this. Contact resistance and oxidation
IMPORTANT! Resistance in connectors, cables and junctions
The multi-pin connectors for the engine control should be close to 0 Ω. A certain amount of resistance
unit must only be checked with gauge 9998482. will occur, however, because of oxidation in
• Carefully insert gauge 9998482 into the multipin connectors.
connector. Pull and push the connector in and If this resistance is too great, malfunctions occur. The
out a few times and feel whether the terminal amount of resistance that can be tolerated before
socket grasps the tool. If the terminal socket malfunctions occur varies, depending on the load in
does not grasp, or if it feels slack, the connection the circuit.
pins should be changed. Please refer to ”Joining
electrical cables for multi-connector” Check the Open circuit
secondary locking in the connector. Possible reasons for faults could be chafed or broken
cables, or connectors which have come undone.
P0008528
P0008529
P0008530
9
869
999 7
6
14
5
13
4 21
12
3 20
11 28
2 19
10 27
1 18 35
9 26
17 34
8 25 42
16 33
24 41
15 32 49
23 40
31 48
22 39 56
30 47
38 55
29 46
37 54
45 62
36 53
44 61
52
43 60
51
59
50
58
57
P0008531
General
If battery voltage falls below 24.7 V (measured at the
battery), the starter motor will not be able to crank the
engine at normal speed. A fully charged battery has an
open circuit voltage of about 25.4 V.
P0008398
P0008399
P0008405
04
P0008406 8
5mm
P0008407
P0008408
Alternator faulttracing
Valid for alternator 20409228.
• NOTICE! Cut the current with the main switch.
• Remove all connectors on the alternator. B+, B–,
etc.
• Remove the plastic cover over the diods. The plastic
cover is fixed with two nuts on B1+, B2+, and a
pozidrive screw.
• Loosen the three screws that holds the brushes and
the regulator.
Energizing sequence
1 When the main switch is closed, the engine
control unit pin A8 (main relay hold) gets battery
potential. Main relay is not activated.
The PCU and HCU are energized (via the engine
connector pin 4).
2 When the starter key is turned to position I
(terminal 15a on the starter switch is connected
to pin 30), the engine control unit pin A58 receives
an activation signal from the PCU via pin 5 in the
engine connector. Pin A8 alter its potential to
approx. 0.8 V and the main relay activates.
When the ignition is switched, the EVC
equipment such as the control panels and
instruments are activated. All relays connected to
the starter switch and start / stop panels are
activated to supply current to equipment which
does not belong to the EVC.
IMPORTANT!
The chassis number or engine serial number must be available to allow the software to be downloaded.
Action:
1 Log in to Volvo Penta Partner Networks web site, http://www.vppn.com
2 Choose ”Vodia” in the left-hand menu.
3 Choose ”ECU Programming” in the left-hand menu.
4 Follow the instructions under ”Download software”. Choose the control units to be re-programmed and click
the ”Download” button. The software for the selected control units is now downloaded to the PDA (Personal
Digital Assistant).
5 Take a look under ”Settings”, ”Software information” in Vodia to check that the software has been
downloaded.
6 Connect the Vodia to the engine to be programmed.
7 Start with the engine control unit. Select ”Engine with mounting and equipment” in the Vodia menu.
Select ”MID 128 Control unit, programming”. Vodia will guide you through the entire programming process.
8 The next control unit is the vehicle control unit, PCU (Powertrain Control Unit). Select ”Electrical system and
instruments” in the Vodia menu. Select ”MID 187 Control unit, programming”. Vodia will guide you through
the entire programming process.
9 The next control unit to be programmed is the HCU (helm station control unit). Select ”Electrical system and
instruments” in the Vodia menu. Select ”MID 164 Control unit, programming”. Vodia will guide you through
the entire programming process.
NOTICE! All helm station control units on the same drive line should be programmed in one sequence.
Function fault
Fault code information
• MID (“Message Indication Description”): • SID (“Subsystem Indication Description”):
The MID consists of a number which designates The SID consists of a number that designates a
the control unit that sent the fault code message. component to which the fault code relates
(e.g. the engine control unit). (tachometer, for example).
• PID (“Parameter Indication Description”): • PSID (“Proprietary SID”)
The PID consists of a number that designates a The same as the SID, but this is a Volvo-specific
parameter (value) to which the fault code relates component.
(oil pressure, for example).
• FMI (“Failure Mode Identifier”):
• PPID (“Proprietary PID”): FMI indicates the type of fault (please refer to
The same as the PID, but this is a Volvo-specific the FMI table below).
parameter.
NOTICE! The following must be done before fault tracing continues, to avoid changing functional sensors:
If VODIA is not able to identify the engine control unit The starter motor is activated with the ignition on.
(MID 128), this will not be visible under ”Vehicle If the starter motor is activated as soon as the switch
information”. is turned, the diode in the key switch cable harness
might be short circuited. Fault trace the diode in
NOTICE! If the engine control unit has not been accordance with the ”Checking the key switch diode”
identified, it can not be programmed. section.
Fault Codes
MID 128, PID 20, Extended Range
Engine Coolant Pressure
MID 128: Engine control unit
Symptom: None
Preconditions: Current below normal or open circuit.
Conditions for fault code: Voltage on engine control unit pin B20 lower than 0.07 volts.
Possible reason: • Open circuit in the sensor 5 V supply cable.
• Open circuit in sensor signal cable.
• Short circuit between sensor signal cable and battery negative to
coolant pressure sensor.
• Faulty sensor.
Suitable action: 1 Check the cable harness between the sensor and the EMS 2.
2 Check contact pressure in socket 18 in engine connector B.
3 Check the sensor.
Circuit description
The sensor is of active type, i.e. it must be supplied
with operating voltage. Pin 17 on engine control unit
(EMS2) connector B supplies operating power of +5
volts to sensor pin 1. Sensor pin 4 is connected to
battery negative via EMS2 pin 18.
The coolant pressure sensor output signal – sensor pin
2 to EMS2 pin 20 – is a voltage signal proportional to
20 GN/SB 2
coolant pressure. The output signal is linear within
sensor working range.
(+)17 R 1
SB
(-)18 4
b a
EMS 2
P0007184
a Coolant Pressure
b Connector B
(Gray)
Measurements
Checking supply cable, coolant pressure
sensor, page 155
Checking negative cable, coolant pressure
sensor, page 155
Checking signal cable, coolant pressure
sensor, page 156
Checking the coolant pressure sensor, page 156
a
Circuit description
The fuel pressure sensor is of active type, i.e. it must
be supplied with operating power.
Engine control unit connector B, pin 17, supplies
GN / BL sensor pin 1 with +5 volts. Sensor pin 4 is connected
to the battery negative terminal via engine control unit
P0007189 pin 18. The pressure sensor output signal – sensor pin
2 to control unit pin 16 – is a voltage signal proportional
a Connector B to fuel pressure measured by the sensor. The output
Color: GrAy signal is linear within sensor working range.
V Component specification
Working range 0–700 kPa (0–7 bar)
Power supply 5.00 ± 0.25 VDC
V Output voltage
kPa Fuel pressure
Measurements
Checking supply cable, fuel pressure
sensor, page 157
Checking negative cable, fuel pressure
sensor, page 157
Checking signal cable, fuel pressure
sensor, page 158
Checking the fuel pressure sensor, page 158
P0007193
a Connector B
Color: GrAy
D9 CC D11, D13
a
R SB Y Y SB R
B AC C AB
a SB
Y Y R /BL
SB
(D13) (D11)
10 R /BL 4(+)
SB R /BL 10 A 2
R /BL 5(+) SB
B
8
Y
EMS2 b 8 C 3
Y
P0007195
EMS2
a Connector B P0008540
Color: GrAy
b Power Module
a Connector B
Measurements
Checking supply cable, water switch, fuel
filter, page 160
Checking negative cable, water switch, fuel
filter, page 161
Checking signal cable, water switch, fuel
filter, page 161
Checking the water in fuel switch, fuel
filter, page 162
Circuit description
P0010640
D16
b
GN/SB 4 1
3
SB c
10 2 3
4 GN/W
a
a Connector A
b Connector B
c Oil temperature and level sensor
GR/OR
31
EMS2
P0008588
D13
P0010638
D11
a
(-)10 SB
(+)57,60 R/BL
a ConnectorA
2
b Connector B
1 c
b 3 c Oil level monitor
GN/W
26
P0008587
Measurements
Checking supply cable, oil level switch, page 164
Checking negative cable, oil level switch, page 164
Checking the oil level switch, page 165
Checking the oil level sensor, page 166
D13 D16
b a
(+)7 R 4 1
17 R 4 1
(-)11 SB
SB P2
18 P2
a EMS2 b c
BL / OR
11 11 BL / OR
EMS2 P0017176
P0017175
P0017175
a Connector A
a Oil pressure sensor
b Connector B
b Connector B
c Oil pressure sensor
Component specification
V Output voltage
kPa Oil Pressure
Measurements
Checking supply cable, oil pressure
sensor, page 172
Checking negative cable, coolant pressure
sensor, page 155
Checking signal cable, oil pressure
sensor, page 172
Checking the oil pressure sensor, page 173
D9, D12
Circuit description
The intake manifold temperature sensor comprises a
thermistor that forms a closed circuit with an internal
resistor in the engine control unit (EMS2). Thermistor
resistance changes non-linearly depending on intake
manifold temperature. EMS2 supplies the circuit with
a reference voltage of +5 volts. EMS2 measures the
voltage drop across the thermistor via EMS2 pins 47
and 11. Sensor pin 1 is connected to battery negative
a ConnectorA via EMS2 pin 11. When intake manifold temperature is
b Air inlet pressure/intake manifold temperature cold thermistor resistance is high and EMS2 detects a
high voltage drop. As intake manifold temperature
rises thermistor resistance falls and voltage drop is
reduced. Refer to the Resistance/temperature table in
D11, D13, D16 this fault code chapter.
a
P0007209
a ConnectorA
b Air inlet pressure/intake manifold temperature
Measurements
Checking negative cable, intake manifold temperature
sensor, page 170
Checking signal cable, intake manifold temperature
sensor, page 170
Checking the intake manifold temperature
sensor, page 171
D9, D12
Circuit description
The charge air pressure sensor is a combined sensor
that also measures intake manifold air temperature.
The sensor is of active type, i.e. it must be supplied
with operating voltage.
Engine control unit pin 7 supplies sensor pin 1 with +5
volts. Sensor pin 4 is connected to battery negative via
engine control unit connector pin 11.
The pressure sensor output signal – sensor pin 2 to
a ConnectorA engine control unit connector A, pin 22 – is a voltage
Color: Black signal proportional to the pressure measured by the
b Air inlet pressure/intake manifold temperature sensor. The output signal is linear within sensor
working range.
D11, D13, D16
Component specification
D9, D12
Working range 40–400 kPa (0.4–4.0 bar)
Power supply 5.00 ± 0.25 VDC
D13
Working range 50–600 kPa (0.5–6.0 bar)
Power supply 5.00 ± 0.25 VDC
Measurements
Checking negative cable, air inlet pressure
sensor, page 178
Checking signal cable, air inlet pressure
sensor, page 178
Checking the air inlet pressure sensor, page 179
Checking supply cable, air inlet pressure
sensor, page 179
p0004941
b Circuit description
a
The coolant temperature sensor consists of a
thermistor that forms a closed circuit with the engine
control unit. A thermistor characteristic is that its
resistance changes non-linearly in relation to the
GR / W
temperature of the medium it measures. Engine
control unit B, pin 27, supplies sensor pin 1 with a
P0007217
reference voltage of +5 volts. Sensor pin 2 is
connected to battery negative via engine control unit
a Coolant temperature sensor connector pin 18.
b Connector B
When the coolant is cold thermistor resistance is high
and the control unit senses a voltage close to the
reference level. As coolant temperature rises
thermistor resistance falls and the voltage drop is
reduced. Refer to the resistance/temperature table.
Measurements
Checking negative cable, coolant temperature
sensor, page 180
Checking signal cable, coolant temperature
sensor, page 181
Checking the coolant temperature sensor, page 182
b Circuit description
a
Engine coolant level is overseen by a level monitor.
Measurements
Checking supply cable, coolant switch, page 182
Checking negative cable, coolant switch, page 183
Checking the coolant switch, page 183
b Circuit description
a
The crankcase pressure sensor is of active type, i.e. it
must be supplied with operating voltage.
Component specification
V Output voltage
kPa Crankcase pressure
Measurements
Checking supply cable, crankcase pressure
sensor, page 184
Checking negative cable, crankcase pressure
sensor, page 184
Checking signal cable, crankcase pressure
sensor, page 185
Checking the crankcase pressure sensor, page 185
Circuit description
EMS2 monitors voltage supply at pins B57 and B60.
SB 1
(-) 18 whose resistance changes depending on exhaust
VO 2 temperature. Resistance increases as exhaust
(+) 44 temperature rises.
2
2
EMS2
D13
Conn. B
1
1
SB 1
(-) 18
GR 2
(+) 44
2
2
EMS2
P0007230
Measurements
Checking signal cable, exhaust temperature
sensor, page 186
Checking negative cable, exhaust temperature
sensor, page 186
Checking exhaust temperature sensor, page 187
a c Circuit description
(+)7 R 4 1
SB The oil temperature sensor is a combined sensor that
(-)11
3 P2 also measures oil pressure.
GR / OR A thermistor characteristic is that its resistance
31
changes non-linearly in relation to the temperature of
EMS2 b the medium it measures. If the oil in the engine is cold,
BL / OR thermistor resistance is high. If the oil temperature
11
rises, thermistor resistance drops. The voltage drop
P0007206 across the thermistor changes as oil temperature
changes.
a ConnectorA
Color: Black The voltage drop is detected via pin 31 on the engine
b Connector B control unit. Engine control unit pin 7 supplies sensor
Color: GrAy pin 1 with +5 volts. Sensor pin 4 is connected to battery
c Oil temperature sensor negative via engine control unit connector pin 11.
Refer to the "resistance/temperature, engine" table.
Measurements
Checking negative cable, oil temperature
sensor, page 188
Checking power supply cable, oil temperature
sensor, page 189
Checking the oil temperature sensor, page 190
Circuit description
D16
b
c
P0007204
a Connector B
b ConnectorA
c Oil temperature and level
Measurements
Checking negative cable, oil temperature
sensor, page 191
Checking signal cable, oil temperature
sensor, page 192
Checking the oil temperature sensor, page 193
Circuit description
When ignition is on the potential on pin B29 is
approximately 10 V. When cranking is requested B29
is connected, via the EMS, to battery negative and the
starter motor is engaged.
Measurements
Checking the starter motor solenoid, page 194
Checking the pre-start relay, page 194
Circuit description
A classified electrical system has no external stop relay
as standard, just a connector for use by an external
stop relay. An external stop relay must be connected
to the system.
Measurements
Checking the external stop voltage
potential, page 195
Circuit description
23 GR/R
2 The sensor is of active type, i.e. it must be supplied
(+)7 R with operating voltage.
1
Engine control unit connector A, pin 7, supplies sensor
(-)11 SB
4 pin 1 with +5 volts. Sensor pin 4 is connected to battery
a negative via engine control unit connector A, pin 11.
EMS2 The pressure sensor pin 2 output signal to engine
P0008475 control unit pin 23 is a voltage signal proportional to
piston cooling oil pressure.
a Piston cooling pressure The output signal is linear within sensor working range.
V Component specification
Measurements
Checking negative cable, piston cooling pressure
sensor, page 176
Checking power supply cable, piston cooling pressure
sensor, page 177
Checking the piston cooling pressure
sensor, page 177
SB
a Circuit description
2
There is a valve in the oil filter bracket that opens and
10 SB P1
closes piston cooling oil supply depending on oil
pressure. If oil pressure is below 240 kPa (D12) or 300
kPa (D16) the valve closes piston cooling oil supply.
14 GR / R
EMS Piston cooling pressure is overseen by a pressure
P0007245 monitor. The monitor output signal – engine control unit
pin 1 – can only have one of two distinct potentials, high
a Piston cooling pressure switch
or low. The monitor is supplied with power by engine
control unit pin 10. A specified pressure limit of 150 kPa
determines when the monitor switches potential.
Monitor potential is low when piston cooling pressure
exceeds this value.
Measurements
Checking negative cable, piston cooling pressure
sensor, page 175
Checking power supply cable, piston cooling pressure
sensor, page 176
a
Circuit description
(-) 11 The sensor is of active type, i.e. it must be supplied
SB b
with operating voltage. Pin 7 on engine control unit
(+ ) 7 1 4
(EMS2) connector A supplies operating power of +5
R P2 volts to sensor pin 1. Sensor pin 4 is connected to
19 battery negative via EMS2 pin 11. The seawater
GR pressure sensor output signal – sensor pin 2 to EMS2
P0007246
pin 19 – is a voltage signal proportional to seawater
a Connector A
pressure.
Component specification
Measurements
Checking negative cable, seawater pressure
sensor, page 173
Checking supply cable, seawater pressure
sensor, page 174
Checking signal cable, seawater pressure
sensor, page 174
Checking the seawater pressure sensor, page 175
FMI 3 – Short circuit to battery voltage, unit injector low voltage side
Fault code explanation: Fault in injection system.
Fault indication: • Warning is displayed in the tachometer/display.
• An orange lamp flashes in the alarm display.
Symptom: • Engine performance is reduced.
• The engine can run on three or five cylinders.
Preconditions: NOTICE! Identify the cylinder by using the SID number in the fault code.
Conditions for fault code: • Injector activated
• Short circuit to battery voltage on the pin on every injector low voltage
side.*
NOTICE! * Engine control unit: Pins 16, 24, 32, 48, 56.
Possible reason: • Short circuit between high voltage and low voltage sides.
• Short circuit to battery voltage, low voltage side, injection cable.
Suitable action: 1 Check the cables between the injector and the engine control unit.
FMI 4 – Short circuit to battery negative, unit injector low voltage or high voltage side.
Fault code explanation: Fault in injection system.
Fault indication: • Warning is displayed in the tachometer/display.
• An orange lamp flashes in the alarm display.
Symptom: • Engine performance is reduced.
• The engine can run on three or five cylinders.
Preconditions: NOTICE! Identify the cylinder by using the SID number in the fault code.
Conditions for fault code: • Injector activated
• Short circuit to battery voltage on the pin on every injector low voltage*
or high voltage side**.
NOTICE! * Pins 16, 24, 32, 40, 48 and 56 on the engine control unit.
** Pins 59 and 60 on the engine control unit.
Possible reason: Short circuit between the cables on every injector low voltage or high voltage
side and battery negative.
Suitable action: 1 Check the cables between the injector and the engine control unit.
b Circuit description
a
D9, D12, D16
The engine's unit injectors have electronically
controlled solenoid valves. The solenoid valve is
controlled by the engine control unit.
a Connector A
b Unit injector, cylinders 1-6
a
Y
b D11, D13
20
24 Y
1 The unit injectors used on D11 and D13 engines have
59 Y two electronically controlled solenoid valves. Each
12
Y solenoid valve is individually controlled by the engine
16 Y
2 control unit.
Y
62
Y The unit injectors receive voltage from pin 59, 60, 61
28 3
32 Y or 62 on the engine control unit. In order to activate a
unit injector solenoid valve the engine control unit
connects the unit injector low side to battery negative.
52 Y
4 Each unit injector is marked with a code on top of the
56 Y
60 Y electrical connection. If a unit injector is replaced the
44 Y new code must be entered into VODIA for the cylinder
48 Y 5 concerned.
61 Y
Y
36
40 Y 6
P0008674
a Connector A
b Unit injector, cylinders 1-6
Measurements
Injector trim, page 167
Checking the injector coils, page 168
P0008694
Measurements
P0007250 Checking camshaft sensor, page 163
a Connector A
b Tachometer sensor (camshaft)
P0008694
P0016316
a Connector A
b Tachometer sensor (flywheel)
Measurements
Checking flywheel sensor, page 160
Circuit description
D12, D13 single turbo (not classified) D12, D13 single turbo
b The engine is equipped with a turbocharger with
waste gate valve. The valve is located beneath the
a protective cover for the relays. The wastegate valve
(+) 57 R / BL controls the amount of exhaust flow that passes
2
(+) 60 R / BL through the exhaust turbine. Air pressure measured
1
in the inlet manifold is used to determine how far the
D12: GN
38
D13: GN / OR wastegate valve will be opened.
EMS2
P0016318 An electronically governed control valve is used by the
engine control unit to control the level of air pressure
a Wastegate Valve supplied to the wastegate valve. When air pressure
supplied to the wastegate valve by the control valve
b Connector B
increases, the valve opens more. When the
wastegate valve is fully open, exhaust gas flow to the
exhaust turbine is at its lowest.
D13CC single turbo The control valve is controlled by current from the
a +15 engine control unit with the aid of a PWM signal. The
58 BL/R greater the current supplied to the control valve, the
greater the inlet pressure increase. Inlet pressure is
2 PM
EMS2 b constantly monitored by a sensor installed in the inlet
manifold.
c 1
38 GN/OR
P0017178
P0017178
a Connector A
b Connector B
c Wastegate Valve
P0010641
P0010639
Measurements
Checking the wastegate valve, page 159
Circuit description
An electromagnetic clutch is used to engage and
disengage the mechanical supercharger. The EECU
activates the coupling by providing the coupling
solenoid with voltage from pin B2. Pin 2 from the
coupling is connected to battery negative.
P0010642
Circuit description
Circuit description
The exhaust manifold water temperature sensor is a
Pt-200 sensor which means that the resistance output
from the sensor is 200 ohm at 0 °C (32 °F). The
resistance will rise with the temperature.
Circuit description
e
PM Circuit description
1 15 29 67 8 14 28 42 As soon as the power module receives power from the
R primary battery or the secondary battery, with main
R battery switches on, the 30 supply output is powered
d
(connected to key switch and MCC / EVC). If the power
SB SB module receives a +15 ignition signal it will activate
c c
EMS2 and extra power outputs (engine mounted
instruments such as EasyLink, External stop and
a b Water in fuel).
P0017212 The power module internal relay function switches
between primary battery and secondary battery
a Primary Battery depending on highest voltage. The two battery groups
b Secondary Battery are never active at the same time. The power module
c Main battery switch monitors the battery voltage level and if it is too low/
high >30 seconds FMI 3/4 is set.
d Starter motor / junction box
e Power Module
e
PM Circuit description
1 15 29 67 8 14 28 42 As soon as the power module receives power from the
R primary battery or the secondary battery, with main
R battery switches on, the 30 supply output is powered
d
(connected to key switch and MCC / EVC). If the power
SB SB module receives a +15 ignition signal it will activate
c c
EMS2 and extra power outputs (engine mounted
instruments such as EasyLink, External stop and
a b Water in fuel).
P0017212 The power module internal relay function switches
between primary battery and secondary battery
a Primary Battery depending on highest voltage. The two battery groups
b Secondary Battery are never active at the same time. The power module
c Main battery switch monitors the battery voltage level and if it is too low/
high >30 seconds FMI 3/4 is set.
d Starter motor / junction box
e Power Module
Circuit description
EVC As soon as the power module receives power from the
primary battery or the secondary battery, with main
HCU
MCC PCU
battery switches on, the 30 supply output is powered
b (connected to key switch and MCC / EVC). If the power
5 4 3
module receives a +15 ignition signal it will activate
R/BL EMS2 and extra power outputs (engine mounted
R
a instruments such as EasyLink, External stop and
10 11
Water in fuel).
EMS2 2 PM The power module internal relay function switches
A58 3
P0017216
between primary battery and secondary battery
depending on highest voltage. The two battery groups
a Power Module are never active at the same time. The power module
monitors the battery voltage level.
b 8-pole connector
(D13)
Circuit description
1 3 BL/R
BL/R 5 2
2 4 BL/R As soon as the power module receives power from the
c b a 13 12 primary battery or the secondary battery, with main
57 60 battery switches on, the 30 supply output is powered
PM
EMS2 (B) (connected to key switch and MCC / EVC). If the power
P0017218 module receives a +15 ignition signal it will activate
EMS2 and extra power outputs (engine mounted
a Power Module instruments such as EasyLink, External stop and
b Emergency Stop Water in fuel).
The power module internal relay function switches
c Shutdown relay (only D13)
between primary battery and secondary battery
depending on highest voltage. The two battery groups
are never active at the same time. The power module
monitors the battery voltage level.
Circuit description
BL/R 1 b As soon as the power module receives power from the
2 1 primary battery or the secondary battery, with main
c GN
battery switches on, the 30 supply output is powered
4 5 A27 (connected to key switch and MCC / EVC). If the power
a PM EMS2 module receives a +15 ignition signal it will activate
P0017253
EMS2 and extra power outputs (engine mounted
instruments such as EasyLink, External stop and
a Power Module Water in fuel).
The power module internal relay function switches
b Easy Link connector
between primary battery and secondary battery
c External stop depending on highest voltage. The two battery groups
are never active at the same time. The power module
monitors the battery voltage level.
Measurements
Checking supply cable, coolant
pressure sensor
Tools:
88890074 Multimeter
9998534 Break-out cable
885675 Break-out cable
Component specification
Working range 0–300 kPa (0–3 bar)
Power supply 5,00 ± 0,25 VDC
885 675
P0008932
D11
1 Remove the switch.
2 Disconnect the connector from the water in fuel
switch.
3 Use multimeter 88890074 to do resistance
measurements.
8856
75
NOTICE! * ±10% at 20 °C (68 °F).
5
4
3
2
V 5 Use multimeter 88890074 for voltage
1
2
1 measurement. Move a metal object rapidly back
885 675
and forth at a distance of no more than 1 mm in front
of the sensor. Check that the multimeter gives a
reading.
6 Install the sensor.
75
8856
5
4
3
2
1
2
1
885 675
P0008931
Tools:
9998534 Break-out cable
885675 Break-out cable
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
P0007205
Injector trim
The electronic trimming strategy is used to ensure that
all injectors work with nominal injection times and fuel
quantities. This is achieved by adjusting the beginning
and end of the electronic wave pattern for every
actuator. In this way compensation is made for the
spread of activation and deactivation times of the two
actuators in each injector, and deviations in fuel
delivery due to variations between the different nozzle
flows are also corrected.
* Black connector A.
** Battery negative (–) on alternator or starter motor.
IMPORTANT!
Take great care when measuring inside the connector
to ensure that no pins are damaged.
D11
Measuring points in Nominal value
connector A at 20 °C (68 °F)
Pin no.
20 – 62 R ≈ 1.4-3 Ω
12 – 62 R ≈ 1.4-3 Ω
28 – 62 R ≈ 1.4-3 Ω
24 – 59 R ≈ 1.4-3 Ω
16 – 59 R ≈ 1.4-3 Ω
32 – 59 R ≈ 1.4-3 Ω
52 - 61 R ≈ 1.4-3 Ω
44 - 61 R ≈ 1.4-3 Ω
36 - 61 R ≈ 1.4-3 Ω
56 - 60 R ≈ 1.4-3 Ω
48 - 60 R ≈ 1.4-3 Ω
40 - 60 R ≈ 1.4-3 Ω
20 - 57 Open circuit
12 - 57 Open circuit
28 - 57 Open circuit
24 - 57 Open circuit
16 - 57 Open circuit
32 - 57 Open circuit
52 - 57 Open circuit
44 - 57 Open circuit
36 - 57 Open circuit
56 - 57 Open circuit
48 - 57 Open circuit
40 - 57 Open circuit
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
9998534
P0007190
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
P0007186
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
P0005119
°C Coolant Temperature
Ω Resistance
°C Exhaust Temperature
Ω Resistance
Measuremen Nominal resistance value Nominal voltage value measured across the
t points sensor
1-2 R ≈ 185 Ω at -20° C U ≈ 0.78 V at -20° C
at
1-2 R ≈ 200 Ω at 0° C U ≈ 0.84 V at 0° C
1-2 R ≈ 220 Ω at 25° C U ≈ 0.90 V at 25° C
1-2 R ≈ 238 Ω at 50° C U ≈ 0.96 V at 50° C
1-2 R ≈ 276 Ω at 100° C U ≈ 1.08 V at 100° C
1-2 R ≈ 313 Ω at 150° C U ≈ 1.19 V at 150° C
1-2 R ≈ 349 Ω at 200° C U ≈ 1.29 V at 200° C
1-2 R ≈ 385 Ω at 250° C U ≈ 1.39 V at 250° C
1-2 R ≈ 420 Ω at 300° C U ≈ 1.48 V at 300° C
1-2 R ≈ 454 Ω at 350° C U ≈ 1.56 V at 350° C
1-2 R ≈ 488 Ω at 400° C U ≈ 1.64 V at 400° C
1-2 R ≈ 521 Ω at 450° C U ≈ 1.71 V at 450° C
1-2 R ≈ 554 Ω at 500° C U ≈ 1.78 V at 500° C
1-2 R ≈ 618 Ω at 600° C U ≈ 1.91 V at 600° C
1-2 R ≈ 679 Ω at 700° C U ≈ 2.02 V at 700° C
1-2 R ≈ 738 Ω at 800° C U ≈ 2.12 V at 800° C
1-2 R ≈ 795 Ω at 900° C U ≈ 2.21 V at 900° C
1-2 R ≈ 849 Ω at 1000° C U ≈ 2.30 V at 1000° C
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
Tools:
9998534 Break-out cable
885675 Break-out cable
88890074 Multimeter
kΩ Resistance
°C Engine Oil Temperature
Nominal value
R ≈ 2-12 Ω*
39-0 General
Adjustment parameters for low-
speed or trolling function
The lowspeed or trolling function can be fine-tuned
using VODIA. Go into “parameter programming” and
adjust the parameters given below.
P0008761
3 Slip valve
4 Secondary solenoid valve
The illustration shows the reversing gear with trolling valve and 5 Cable marking ”SECONDARY”
cables connected for left-hand rotation.
6 Cable marking “PRIMARY”
P0008762
Index
MID 128: Engine control unit
Caption PID PPID SID PSID FMI
MID 128, PID 20, Extended Range Engine Coolant 20 1, 3, 5
Pressure, page 74
MID 128, PID 94 Fuel Delivery Pressure, page 76 94 1, 3, 5, 7
MID 128, PID 97 Water in fuel indicator, page 79 97 0, 3
MID 128, PID 98 Engine oil level, page 83 98 1, 3
MID 128, PID 100 Engine oil pressure, page 86 100 1, 3, 5
MID 128, PID 105 Intake manifold temperature, page 89 105 0, 4, 5
MID 128, PID 106 Air inlet pressure, page 92 106 0, 3, 5
MID 128, PID 110 Engine coolant temperature, page 95 110 0, 4, 5
MID 128, PID 111 Coolant level, page 98 111 1, 3
MID 128, PID 153 Crankcase pressure, page 100 153 0, 3, 5
MID 128, PID 158 ECU battery potential, page 103 158 1
MID 128, PID 163, Transmission range attained, page 104 163 9
MID 128, PID 173 Exhaust gas temperature, page 105 173 0, 4, 5
MID 128, PID 175 Engine oil temperature, page 107 (D9, D11, 175 0, 4, 5
D12)
Engine Oil Temperature (D16) 175 0, 4, 5
MID 128, PID 190 Engine speed, page 113 190 0
MID 128, PPID 3 Starter Output, page 114 3 3, 4, 5
MID 128, PPID 6 Key off input sensor, page 115 6 4, 11
MID 128, PPID 8 Piston Cooling Oil Pressure, page 117 (D9, 8 1
D12, D16)
Piston cooling oil pressure (D11) 8 1, 3, 5
MID 128, PPID 98 Engine sync acknowledge, page 121 98 9
MID 128, PPID 117 Engine protection status, page 122 117 7
MID 128, PPID 132 Throttle Calibrated Position, page 123 132 9
MID 128, PPID 267, Sea water pressure, page 124 267 1, 3, 5
MID 128, SID 1/2/3/4/5/6 Injector # 1-6, page 126 1/2/3/4/5/6 3, 4, 5, 7, 12
MID 128, SID 21 Engine position, page 130 21 2, 3, 8
MID 128, SID 22 Timing sensor, crank, page 133 22 2, 3, 8
MID 128, SID 32, Wastegate output driver, page 137 32 3, 4, 5
MID 128, SID 89 Air Compressor Actuator Circuit, page 140 89 3, 4, 5
MID 128, SID 232 5 V supply, page 142 232 3, 4
MID 128, SID 240 Program memory, page 143 240 2
MID 128, SID 254 Controller 1, page 144 254 3, 12
MID 128, SID 231 SAE J1939 data link, page 145 231 2, 9
MID 128, PSID 112 Exhaust Manifold Water Temperature 112 0, 3, 4, 5
Sensor #1, page 146
MID 128, PSID 216 Data Link, MID187, page 148 216 9
202
References to Service Bulletins
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AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
47700583 English 08--2017