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1241 WS4

1. 27 Erasing error codes AA 28 General 8 Error codes EDC Ill 29 Location of engine plates 8 Electronicfaultdetection 46 Eelere 9 General 46 Special tools 9 Functionality check of cables and connectors 46 Fault detection on cables and connectors 47 Technical data AAA 10 Splicing electrical cable for cable glove 48 Check fault detection of components 49 Design and operation 12 System description EDC Ill 12 Electrical System AAA 62 Component description sensors and monitors 14 Important about the electrical system 62 Electronic Control unit ECU 16 Electrical system overview 63 Control Interface Unit CIU 16 Wiring diagram TAD1240 42GEV VE 66 Unit INO CONS sisie 17 Wiring diagram TWD1240VE 67 GONeratOr n cece eeeteeeeeeteeeeeeeeeeteeaeeeeenaeeeeeaes 17 Wiring diagram Control Interface Unit CIU 68 Starter MOTON eeeececeeeeeeceeeeteneeeeesteeeeeeeeeteaes 17 Wiring diagram Control Interface Unit CIU Component diagram and location
2. 5 Check fault detection of components 49 Component description sensors and monitors 14 Component diagram and location 18 Control Interface Unit CIU 16 Control module EMS 16 Control module EMS replacement sssessieesee 23 D Design and operation 12 Diagnostic function affects the engine 27 DiagQnostic fUNCTION cee eeeeeeeeeeeeeeteeeeeeeeeeenaes 27 E Electrical evstenm ccceceesssccceeeeenseeeeeeeeeeteees 62 Electrical system overview 63 Electronic fault detection 46 Erasing Crror COGS esnin 28 F Fault codes EDC III iscsscssscccesesccnncendccnsstxecsavseacrvees 29 Fault detection of cables and connectors 47 Fault GOTO CHON sissies 26 Functionality check of lines and connectors 46 Functionality check 25 G General au u Sa l AT 8 General information 5 General u u u a uu 2 sss 46 EN EE 17 l Important about the electrical system 62 niet Le EE 2 L Limit Valu8S_ posis iiginn ranra 19 Limit values control unit ECU TAD1240 42GENVE 19 Limit values control unit ECU TWD1240VE asas aaas 20 Limp homevalues
3. 18 Power B80K as asasassassacaagkapaqkapssyasass 69 Limitvalues I aa l 19 Je EE 70 Limit values control unit ECU TAD1240 42GE V E AAA 19 Limit values control unit ECU TWDI240VE kiasia adenn aa aa aiaia 20 Limp home values 21 Group 23 EDC III Safety information Safety information Introduction This Service Manual contains descriptions and repair instructions for the Volvo Penta products or product versions listed in the table of contents This manual should be used together with the Service Manual Technical data for the relevant engine Be sure to use the correct service literature Carefully read the safety information and General information and Repair instructions in the Service Manual before starting service work Important The following special warning symbols are found in the Service Manual and on the engine ZX WARNING Warns for the risk of injury damage to the product or property or that serious mal functions could arise if the instructions are not followed Z IMPORTANT Used to draw attention to any thing that could cause injury or the malfunction of a product or property NOTE Used to draw attention to important information to facilitate work operations or handling To provide an overview of the dangers of which you should always be aware and the precautionary measu res that should always be taken we have listed them here
4. 67 Wiring diagram Control Interface Unit CIU ower DQ0K u ass sassa aqaasunaqapakaqsayyan qusaqa waayys 69 Wiring diagram Control Interface Unit CIU 68 Report form Do you have any complaints or other comments about this manual Please make a copy of this page write your comments down and post it to us The address is at the bottom of the page We would prefer you to write in English or Swedish AB Volvo Penta Customer Support Dept 42200 SE 405 08 Gothenburg Sweden 900 r0 Ueifu ZSLELPLL
5. Check the system pressure valves and the safety valve in the oil system Check the function of the oil pressure sensor 110 Code 7 1 Cause Unit injector cylinder 1 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 37 Group 23 EDC III 111 Code 7 1 Cause Unit injector cylinder 1 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action e Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 112 Code 7 1 Cause Unit injector cylinder 1 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 113 Code 7 1 Cause Unit injector cylinder 1 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 114 Code 7 1 Cause Error in compression or the unit injector
6. 29 Group 23 EDC III 102 Code 2 5 Cause RPM sensor camshaft No signal Response The engine takes longer than normal to start The engine runs normally once underway Corrective action e Check that the tachometer sensor connector is fit ted correctly Check that the wiring to the tachometer sensor is not damaged Check that the tachometer sensor is correctly fit ted in the upper timing cover Check the function of the tachometer sensor Check the contact pressure in sleeves 7 and 18 in the black cable glove of the engine control unit ECU 103 Code 2 5 Cause RPM sensor camshaft Abnormal frequency Response The engine takes longer than normal to start The engine runs normally once underway Corrective action Check that the tachometer sensor connector is fit ted correctly e Check that the wiring to the tachometer sensor is not damaged Check that the tachometer sensor is correctly fit ted in the upper timing cover Check the function of the tachometer sensor 23 Code 2 7 Cause RPM potentiometer connected to engine con trol unit ECU Interrupted or shorted to positive Response The engine goes to idle If the pedal is re leased and then depressed again the engine can limp home using the idle contact Corrective action Check the the control s connector is fitted correctly Check that the wiring to the sensor is not damaged Check the function of th
7. N Make it impossible for the engine to start Turn off the current by means of the main switch or switches and lock it them in the off position before starting service work Affix a warning sign in the driver s area A Asarule all service work should be performed when the engine is switched off However some work such as certain adjustments requires the engine to be running Approaching a running engine could be dangerous Bear in mind that loose fitting clothes or long hair could get caught in rotating parts and cause serious injury A If work is performed near a running engine an incautious movement or dropped tool could in the worst case lead to bodily harm Be mindful of hot surfaces exhaust pipes the turbochar ger charge air pipes starter elements etc and hot liquids in lines and hoses on an engine that is running or has just been stopped Before star ting the engine refit all guards and protective elements that were removed in the course of performing service work A Make sure that the warning and or information decals affixed to the product are always in plain sight Replace any decals that have been dama ged or painted over N Never start the engine unless the air filter is fitted The rotating impeller in the turbocharger could cause serious injuries Foreign objects in the inlet line could also cause machinery damage N Never use starter spray or the like to help start the engine It could cause a
8. Corrective action Check that the connector of the charge air pressu re sensor is fitted correctly Check that the wiring to the charge air pressure sensor is not damaged Check that the charge air pressure sensor is fitted correctly e Check the function of the charge air pressure sen sor Check the contact pressure in sleeve 3 in the black cable glove of the engine control unit ECU 184 Code 3 7 Cause Oil temperature sensor Interrupted or shorted to positive Response None Corrective action Check that the wiring to the oil temperature sen sor is not damaged Check that the oil temperature sensor is correctly connected Check the contact pressure in sleeve 1 in the black cable glove of the engine control unit ECU 32 Diagnostic function 185 Code 3 7 Cause Oil temperature sensor Short to negative Response None Corrective action e Check that the wiring to the oil temperature sen sor is not damaged Check that the oil temperature sensor is correctly connected 200 Code 4 1 Cause Oil pressure alarm circuit interrupted Response Alarm lamp does not work If the circuit is interrupted during start up diagnostics are deacti vated Corrective action Check the alarm lamp Check that the wiring to the alarm lamp is not da maged Check sleeve L in the 23 pin connector Check the contact pressure in sleeve 35 in the red cable glove of
9. The voltage re gulator then compensates for any voltage drop in the lines between the generator and the battery by increa sing the charging voltage from the generator as needed Starter motor 16 The starter motor is mounted on the flywheel housing on the right hand side of the engine When the motor is cut in a gear on the armature shaft of the starter motor is moved along the axis so that it meshes with the gear ring of the engine s flywheel The actuator solenoid of the starter motor controls both the axial movement of the gear and connection of the starter motor In turn the actuator solenoid of the starter motor is cut in via the start relay which is activated when the ignition key is turned to position III or the start button is depressed The starter motor relay 1 is mounted next to the star ter motor solenoid Design and operation Group 23 EDC III COON OP ON Design and operation Component diagram and location Coolant level monitor Tachometer sensor camshaft Connection diagnostic tool Programming plug Charge air pressure temperature sensor Extra stop Main relay Generator Fuse 10A Oil pressure temperature sensor Inside the Cover 18 Ti 12 13 14 15 16 17 18 19 20 Control unit ECU Fuel pre
10. PFESSUIE Signal uuu u ss asss 0 5 4 5V Workareatemperature 40 C 40 F to 140 C 284 F RE NTC Negativ Terminal Coefficient Combined sensor charge air pressure temperature VE EE 5V CONMCCION 5 i ccstefiviila eased nes chia 4 pin Work area pressure 1 5 8 58 psi 0 4 4 BAR Pressure sign 0 5 4 5V Workareatemperature 40 C 40 F to 125 C 257 F VY DG seui NTC Negativ Terminal Coefficient Decreased Resistance with increased temp 10 Group 23 EDC III Sensor coolanttemperature Ve Ee E 5V CONNCGIOF ET 2 pin Workareatemperature 40 C 40 F to 150 C 302 F NK NTC Negativ Terminal Coefficient Monitor coolant level Connected to ground The switch is closed when the coolant level is loo low Connector 2 pin pat tY PO smio iguspa ua ansa Closed when coolant level is low Unitinjector tee 90 V CONMOECHION ayau manaa kanaa E RE 2 poles Injection pressure RRE 26100 psi Generator VON E 24V CONNECHION eege siiani eee 2 poles ET 60 A Starter motor e Ee 24 V ASONMOCUOM asirans a a E 2 poles E LEE 6 KW Decreased Resistance with increased temp Technical data Group 23 EDC III Design and operation Design and operation System description EDC Ill EDC III El
11. Penta 11610995 Permatex No 77 In all cases old sea lant can be removed with denatured alcohol 2 Anaerobic agents These harden in the absence of air They are used when two solid parts like cast com ponents are fitted together without a gasket They are also commonly used to secure and seal plugs the th reads of studs cocks oil pressure monitors etc Hardened anaerobic agents are glass like they are therefore colored to make them more visible Harde ned anaerobic agents are highly resistant to solvents and old agent cannot be removed When refitting a component thorough degreasing is required followed by application of fresh sealant The following agents are anaerobic Loctite 572 white Loctite 241 blue Note Loctite is a registered trademark of the Loctite Corporation Permatex is a registered trademark of the Permatex Corporation Group 23 EDC III Location of engine plates The plate below shows 1 Engine designation 2 Serial number 3 Specification number VOLVO PENTA H vox cn T E YRRERXARYX 12 fr KAN XXA 13 A General General The plate below shows 1 Engine designation 2 Specification number 3 Serial number last six digits engine block SOK XXXXXXX4 XXXXAXAXAXKA X The plate below shows A Engine designation Net engine out
12. Several different types of sealants and locking fluids are used on the engine Their properties differ and they are intended for joints of different strengths tem perature ranges resistance to oil and other chemicals and for the various materials and clearances in the engine For service work to be fully satisfactory it is important that the right types of sealants and locking fluids are used on the joints where such are required In the appropriate sections of the Service Manual we have indicated the agents used in the production of our engines Similar agents or agents with corresponding properties but from a different manufacturer should be used in connection with service work When using sealing agents and locking fluids it is im portant for the surfaces concerned to be dry and free from oil grease paint rust inhibitor and residue from old sealant Always follow the directions of the manu facturer regarding temperature hardening time and other instructions relating to the product Two different basic types of agent are used on the engine These are characterized by 1 RTV agent Room Temperature Vulcanizing Used mostly on gaskets e g sealing gasket joints or coa ted on gaskets RTV agent is perfectly visible when the component has been dismantled and old RTV agent must be removed before the joint is sealed afresh The following agents are of RTV type Loctite 574 Volvo Penta 8408791 Permatex No 3 Volvo
13. applies for all in strument boards together Electric welding Remove the positive and negative cables from the batteries Then remove all connections to the generator Then remove the cable glove from the control module EDC III See the instructions in Control module EMS replacement Always attach welding clamps to the part that is to be welded as close to the welding area as possible The clamps must never be attached to the engine or in such a way that current can pass over any bearing N Important After welding the removed compo nents such as cable glove generator cable and battery cables must be refitted in the correct or der Group 23 EDC Ill Electrical system Electrical system overview TWD1240VE Stand alone 63 Group 23 EDC Ill Electrical system TWD1240VE Power pack Sf encase a Te St e t e TAD1240 42GE with CIU CAN based SAE J1939 TAD1241 42VE with CIU CAN based SAE J1939 SE bie 64 Group 23 EDC III Electrical system TAD1240 42GE Stand alone TAD1241 42VE Stand alone 65 Electrical system Group 23 EDC III A tz Mpeg ainssaid ainyesadua
14. damaged Diagnostic function 209 Code 5 3 Cause Stop input on CIU Short to negative Response The engine can only be stopped using the emergency stop on the engine Corrective action Check that the connections to the ignition key are not damaged Check that the wiring to the ignition key is not damaged 211 Code 5 3 Cause Stop input on CIU Short to positive or ac tivated too long Response The engine stops After 40 seconds an er ror code is shown During this time the engine cannot be started When the error code is blinked out on the diagnostic lamp the engine can be started but not stopped Corrective action Check that the connections to the ignition key are not damaged Check that the wiring to the ignition key is not damaged 214 Code 5 3 Cause Stop input on CIU Interrupted or activated too long Response The engine stops After 40 seconds an er ror code is shown During this time the engine cannot be started When the error code is blinked out on the diagnostic lamp the engine can be started but not stopped Corrective action Check that the connections to the ignition key are not damaged Check that the wiring to the ignition key is not damaged 35 Group 23 EDC III 74 Code 5 4 Cause Preheating relay Connection interruption Response Preheating cannot be activated Corrective action e Check that the wiring to the input on the relay is not damaged C
15. is too low Response The engine has decreased performance Corrective action Check the function of the air filter Check the function of the turbocharger Check the function of the charge air pressure sen sor Check the fuel feed pressure 63 Code Cause Voltage feed to sensor Short to positive Response Several error codes for sensor error Corrective action Check the contact pressure in sleeve 5 in the black cable glove of the engine control unit ECU 44 Diagnostic function 64 Code Cause Voltage feed to sensor Short to negative Response Several error codes for sensor error Corrective action Check the contact pressure in sleeve 4 in the black cable glove of the engine control unit ECU 173 Code Cause Datalink J1708 error engine control unit ECU Response Diagnostic lamp shows only CIU internal errors Corrective action Check that the 8 pin connector is not damaged Check that the 8 pin cable between the CIU and the engine control unit ECU is not damaged Check that pin sleeve 22 and 37 in the connector on the CIU are not damaged Check the contact pressure in sleeves 25 and 26 in the red cable glove of the engine control unit ECU 176 Code Cause Monitor for water in the fuel or low fuel pressure Short to positive Response None Corrective action e Check that the wiring is not damaged 186 Code Cause Memory error in t
16. llo iosu s JOJOW JouEIe Joyesauay JOSUSS dy I8SuM ld Josuas dy yeyswey uoneadde jasuay JO ajqeyreAae JON uogoun yeayod ainsseid ainyesoduua 16 aBseyo Josus Josues ainyesaduia lue ooo 10 9fu yun n93 III OGA HUN josyjuoD yoe q L ioljo uuoo pau Z 1ojo uuoo Bnid Bulwweibolg dois I A98 JU OOD iolluolAj ainssaid ont iolluolN AE uren yeyoos Aejoy Jan u 1 EA JO UO polq 1o 99uuooS Bulwwesbolg 10 99uuoo Ae saye BelloA ay sod Aueupg Ane6 u Aieugeg snq NYO 6E6Ir snq gS r 1e1Auql yxS N ay sod Aueupg Ane6 u Aieugeg Ae saye BelloA wieje p dsi AO Buluuns aufue 1ioleSIpul wueje ainyesaduuia yuejooo uBiH uup je ainssaid jlo MOT sonsoubeiq yoejuoo doe JORJUOD ap JORUOD Juge yoeuod 008 00SL Joyawonuejod Walt Q c iO GG lt o G Ch LV OV GE EIS LE OC GE VE E SE LE OC Ge EI Le E Ge P Ce Ce Le OZ EI EI ZL Q c TWO uid z BelloA uu ls s A pZ s AZbr LreLGV1 3DZr 0rZLGV L 24 A a D ZE SS AY SCH T sanan EE e e SE KE Lil Dn a 2p E Be j wE SS be m l 1 E ey d Ei i i me H a 2 oi Rou Ce IR lt 1 DH DI w i i i zk f pre EE a Ree amp amp E F fe WAS A DES r Lac i cc td esp EE ou HO a Je MOIEK E A Ae 9 w H 9 E
17. off when pressure falls below 29 psi 2 BAR Design and operation Group 23 EDC III Coolant level monitor 1 This monitor is located in the expansion tank Its task is to detect if the coolant level in the cooling system expansion tank is too low The monitor con sists of a contact that can be actuated magnetically A hull located around the monitor actuates the contact differently depending on the coolant level An alarm signal is sent if the coolant level is too low Electronic Control Unit ECU 11 The control module EMS checks and controls the unit injectors so that the correct amount of fuel is in jected into each cylinder It calculates and sets the in jection angle This control is done primarily with the help of the tachometer sensors and the combined sensor for charge air pressure temperature The EDC III system processor is located in the con trol unit protected from moisture and vibrations The processor continually receives information regar ding engine speed charge air pressure charge air temperature coolant temperature oil pressure oil temperature fuel alarm combined alarm for water in fuel and fuel pressure coolant level This information is used to make exact determinations on current operating conditions and allows the proces sor to calculate the correct amount of fuel check the condition of the engine etc Control Interface Unit CIU The CIU is a co
18. reasons cer tain components are sealed at the factory Work on these components must not be performed by persons not authorized for such work Bear in mind that the majority of chemical products if incorrectly used are hazardous to the environment Volvo Penta recommends the use of biologically de gradable degreasers for all cleaning of engine compo nents unless otherwise expressly stated in the Servi ce Manual Take care to ensure that oils and residual detergent etc are dispatched for destruction and do not inadvertently end up in the environment Tightening torques Tightening torques for vital bolted joints that should be tightened using a torque wrench are listed in Techn cal Data Tightening torques and are also given in the Service Manual s work descriptions All tightening tor ques refer to cleaned threads bolt heads and contact surfaces as well as lightly oiled or dry threads If lubri cants thread locking compounds or sealants are re quired for bolted joints the type concerned is stated in the work description and in Tightening torques The general tightening torques in the table below are appli cable to bolted joints for which no special tightening torque is specified The tightening torque is a guiding value and the joint need not in such case be tightened using a torque wrench Size Tightening torque Nm Ibf ft M5 6 4 4 M6 10 7 4 M8 25 18 4 M10 50 36 9 M12 80 59 0 M14 140 103 3 Group 23
19. system Wiring diagram Control Interface Unit CIU Cable colors Power pack BL Blue P Pink 1 Activating operating power contact 15 LBL Lightblue R Red 2 RPM potentiometer BN Brown SB Black 3 Tachometer code 14 LBN Lightbrown VO Violet 4 Oil pressure instrument GN Green W White 5 Coolant temperature instrument GR Gray Y Yellow 6 Instrument illumination OR Orange 7 Starter contact non locking 8 Stop contact non locking 9 Diagnosis contact non locking 10 Charge indicator 11 Alarm high oil temperature k N Alarm high coolant temperature Alarm coolant level Fuel alarm Diagonotic lamp Preheating indicator 8 pin Deutsch connection pin 8 pin Deutsch connection sleeve Horn total alarm Preheating contact non locking function option 42 pin connector Termination 120 W N NO N i lt Cre Cee Cre Cr N O O Q G N CA Extra outlet for 24 V and stop 28 99 Control Interface Unit CIU IW 24 Ree Ae WGN Gi DEL is ERED B 33 l m I a C St DOE R BL qa 34 LBN 36 BBS Gei ABI o H 1 E y ga AGN 62 DEL 20 i7 ZE al BEL 19 7 Keier e DEL 69 Group 23 EDC III Index A About the Service Manual eeeeeeeeeeeeee 5 C Certified engines
20. the engine control unit ECU 201 Code 4 1 Cause Oil pressure alarm Short to negative Response Alarm lamp lights constantly Corrective action Check that the wiring and connection to the alarm lamp are not damaged 202 Code 4 1 Cause Oil pressure alarm Short to positive Response Alarm lamp does not work If the circuit is interrupted during start up diagnostics are deacti vated Corrective action Check that the wiring and connection to the alarm lamp are not damaged Group 23 EDC Ill 35 Code 4 2 Cause Alarm for high coolant temp Linked to Stand Alone interface Short to negative Response Alarm lamp lights constantly Corrective action e Check that the wiring to the alarm lamp is not damaged Check that the alarm lamp is fitted correctly 36 Code 4 2 Cause Alarm for high coolant temp Linked to Stand Alone interface Short to positive Response Alarm lamp does not work If the circuit is interrupted during start up diagnostics are deacti vated Corrective action Check that the wiring to the alarm lamp is not damaged Check that the alarm lamp is fitted correctly 226 Code 4 2 Cause Alarm for high coolant temp Circuit interrup tion Response Alarm lamp does not work If the circuit is interrupted during start up diagnostics are deacti vated Corrective action Check the alarm lamp for high coolant temperature e Check that the wirin
21. to the unit injector are not damaged 143 Code 7 4 Cause Unit injector cylinder 4 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action e Check that the wiring to the unit injectors is not damaged e Check that the connections to the unit injector are not damaged Group 23 EDC Ill 144 Code 7 4 Cause Error in compression or the unit injector on cy linder 4 Response Cylinder balance is adversely affected gt Uneven running at low RPM and low load Corrective action Check the fuel feed pressure Check the valve clearance Check that the unit injector and connection cable are not damaged e Doa compression test and check cylinder 4 145 Code 7 4 Cause Unit injector cylinder 4 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check the contact pressure in sleeve 34 in the black cable glove of the engine control unit ECU Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 150 Code 7 5 Cause Unit injector cylinder 5 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector ar
22. 4 pin adapter 9998534 between the sensor connector and the engine wiring Then connect multimeter 9510060 8 between measurement points 1 4 3 Switch on the operating voltage 4 Measure using a multimeter set to measure voltage Check that the multimeter reads 5 0 volts 5 Thenconnect the multimeter between measurement points 2 4 The voltage should be about 1 2 V at normal atmospheric pressure Checking charge air temperature 1 Disconnect the connector from the charge air pressure sensor 2 Connect 4 pin adapter 9998534 between the sensor connector and multimeter 9510060 8 3 Measure with the multimeter set to measure resis tance between the measurement points of the adapter The multimeter should show the following values Measurement points Desired values 34 R 6 2 kQ 20 C 68 F 34 R 2 5 KQ 40 C 104 F NOTE Even if resistance values follow those in the above table it is no guarantee that the sensor is fault free Electronic fault detection Checking the coolant temperature sensor 1 Disconnect the connector and remove the sensor from the engine 2 Use mulitmeter 9510060 8 to measure between both contact pins of the sensor The multimeter should show the following values at 0 C 32 F 4930 Q 440 Q 20 C 68 F 1870 Q 140 Q 40 C 104 F 800 Q 50 Q 60 C 140 F 370 Q 209 80 C 176 F 19002 8Q 100 C 212 F 1042 40 NOTE The sensor is extremely sensitive to changes in t
23. 5 cylinders sounds uneven and has decreased performance Corrective action Check the contact pressure in sleeve 35 in the black cable glove of the engine control unit ECU Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 160 Code 7 6 Cause Unit injector cylinder 6 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injector is not da maged Check that the connection to the unit injector is not damaged 42 Diagnostic function 161 Code 7 6 Cause Unit injector cylinder 6 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action e Check that the wiring to the unit injector is not da maged e Check that the connection to the unit injector is not damaged 162 Code 7 6 Cause Unit injector cylinder 6 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injector is not da maged e Check that the connection to the unit injector is not damaged 163 Code 7 6 Cause Unit injector cylinder 6 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Ch
24. Abee 21 Location of engine plates 8 LOCK ul u ua u a u E 7 70 Index O Our common responsibility 6 P PC diagnostics Program ua au aauaskaqassns 25 R Reading out error codes 27 Repair instructions u 6 Repairinstructi ns u ua s ewssasa 22 s Safety information 2 Sealants H Spare Parts EEN 5 Special Tools spiiinneadb 9 Splicing of electrical cable for cable glove 48 Start with booster batteries 24 Starter MOto sse ciasna ioari iiaia 17 Strength classes a H Symptoms and possible causes sseseeeeeeeee 26 System description EDC Ill 12 T Technicaldata UU UL Uu aaa aasawa 10 The role of diagnostic function 27 Tighteningtorques 6 Torque angletightening 7 U Unit injeglors U LLL in 17 w When working with EDC Ill 22 Wiring diagram TAD1240 42GE VE 66 Wiring diagram TWD1240VE
25. EDC III Torque angle tightening In torque angle tightening the bolted joint is tightened to a specified torque and then additionally tightened through a predetermined angle Example at 90 angle tightening the joint is tightened an additional 1 4 turn after the specified tightening torque has been reached all in the same operation Lock nuts Lock nuts that have been removed must not be reu sed New ones must be fitted instead as the locking characteristics of the old nuts deteriorate or are lost if used several times For lock nuts with a plastic insert e g Nylock the tightening torques in the table should be reduced if the Nylock nut has the same height or thickness as a standard all metallic hex nut Reduce the tightening torque by 25 for 0 32 or larger bolt si zes For higher or thicker Nylock nuts where the all metallic thread is as high as that of a standard hex nut the tightening torques in the table are applicable Strength classes Nuts and bolts are divided into different strength clas ses the strength class is marked on the bolt head A higher number indicates a stronger material For ex ample a bolt marked 10 9 is stronger than one mar ked 8 8 When undoing bolted joints it is therefore im portant to make sure that the bolts are refitted in their original places When fitting new bolts check the spa re parts catalogue to ensure that the correct type is used Repair instructions Sealants
26. ER ait 14 Insufficient air supply to 23 High oil level ae Fuseonuaingboxbiown engine te 24 Generator drive belt is slipping 5 Faulty starter switch tlegoed airther y air leak between turbo 25 Waterinengine 6 Faulty main relay EH engine s intake 26 Greatcounterpressure in 7 Faulty starter motor relay mene exhaust system fouled compressor 8 Faulty starter motor solenoid in turbocharger 27 Interruption cable Pot to 9 Fuelshortage faulty turbocharger pedal fuel cocks closed Ee compartment 28 Highoil temperature ventilation fuel tank empty wrong tank 29 High charge air temperature connected 15 High coolanttemperature 10 Clogged fuel fine filter pre filter 16 Lowcoolanttemperature due to contaminates or 17 L illevel paraffin deposits in the fuel at ee low temperature 18 Low coolant level 19 Air in coolant system 26 Group 23 EDC III Diagnostic function Diagnostic function Diagnostic function The diagnostic function checks that the EDC III sys tem is functioning normally The diagnostic function performs the following tasks Detects and localizes disturbances Notifies when disturbances are detected Provides guidance for fault detection Protects the engine and ensures that the machine remains in working order when serious disturbances are detected 1 Notification of disturbance If the diagnostic function detects a disturbance in the EDC Ill system the opera tor is notifie
27. F D g D E H EI a 1 1 1 IMUM M u N mem GC KH Ion OA uMoiqy6q NAI i i d i E Gh en du F b D eld gS umolg Ng it t a a d peu H ongf 11 i Po as Mud d eng 8 o I 1 jji 1 i zt m op 1 T Siolo5 qeO LAL h u is it bf P i Ze ee gege E eee q L Q i 66 Electrical system Group 23 EDC III A vz Mopeg inss id esnyesadwi9 10 IoSUaS JOJOW Jupe JoyeJauay JOSUdS dy I8SuA d Josuas Wd yeyswed Bune u ud Aejay Buneeuald ainsseid einyesodua ure aey yosues Josuas ainyesaduia juejOOD 9 1 WO siolo lu yun NOA IIIOq3 Wun Ionuoo yorlq L 40 09UU0D pau z 40 99UUOD I A98 JUL OOD iolluolAj ainssaid ont Iolluo N 6nId Burwwesbold Aejay yeyoos Aejay Jen u JeyEM OPUN uoyng dos po q 10 p uuoo Buluuule1Boid Jo12euu0o7 Ae saye abeyo anyisod Auge Ane6 u Aueyeg snd NYO 6 6Lf snq 2894F ny sod A yeg Aay 0 WayshS Ane6 u Aueyeg Key Jaye abeyo Joyeolpul Buryeayeaid Wee A JUB OOD MOT LUSIE ainyeseduua yuejood UI wueje ai
28. TE The entire diode package is insulated from the body of the generator 58 Electronic fault detection Group 23 EDC Ill Checking excitation diodes 1 2 Set the multimeter for diode measurement Connect the negative test probe to D and the po sitive test probe to each of the three stator win dings Take readings of the three stator windings Switch the test probes and take three more readings One time the instrument should read 400 1200mV conducting direction The other time it should read OL Electronic fault detection UL O _ 59 Group 23 EDC III Checking stator windings 1 2 Set the multimeter for diode measurement Connect the test probes between the phase con nections Take three readings The instrument should show the same value for all three readings Overload test on stator 1 2 60 Set the multimeter for diode measurement Connect the test probes between the stator body and one of the three stator windings The instrument should read OL If any other value is shown the stator is short cir cuited Electronic fault detection Group 23 EDC Ill Checking the rotor 1 2 3 Set the multimeter for diode measurement Connect the test probes to the slip rings The instrument reading should be nonexistent or very weak At the same time ch
29. The black jumper cable must ab solutely not come in contact with the positive lead s connection to the starter motor 4 Start the engine and run at high idle about 10 minutes to charge the batteries A WARNING Approaching or working on a running engine is a safety risk Beware of rotating parts and hot surfaces Do not touch the connections during the start at tempt Risk of sparks Do not lean over any of the batteries 5 Switch off the engine Remove the jumper cables in reverse order from fitting One cable at a time 24 Group 23 EDC III Functionality check Functionality check PC diagnostics program This program can read error codes that are stored in the engine control unit check input and output signals read current values from engine sensors and then store and print test results The program enables service and workshop personnel to quickly localize and remedy errors in the EDC Ill system A data link connector is used to connect to the engine control unit User information is included in the program Contact your Volvo Penta dealer to order software The role of the diagnostic function is to detect and localize disturbances in the EDC III system protect the engine and ensure that the machine remains in working order during serious disturbances If a disturbance arises the diagnostic indicator on the indicator panel begins blinking When the diagnosis button is pressed an error code is given as guidanc
30. The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged Group 23 EDC Ill 123 Code 7 2 Cause Unit injector cylinder 2 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action e Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 124 Code 7 2 Cause Error in compression or the unit injector on cylinder 2 Response Cylinder balance is adversely affected gt Uneven running at low RPM and low load Corrective action Check the fuel feed pressure Check the valve clearance Check that the unit injector and connection cable are not damaged Do a compression test and check cylinder 2 Check the fuel feed pressure 125 Code 7 2 Cause Unit injector cylinder 2 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check the contact pressure in sleeve 22 in the black cable glove of the engine control unit ECU Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged Diagnostic function 130 Code 7 3 Cause Unit injector cylinder 3 Electr
31. Workshop Manual Group 23 EDC III TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE EDC Ill TAD1240GE TAD1241GE VE TAD1242GE VE TWD1240VE Contents Safety information aa eee 2 Repairinstructions a 22 Introductio socie ei 2 When working with EDC Ill 22 Control unit ECU replacement 23 General information aee eee 5 Start with booster batteries 24 About the Service Manual eeee 5 Spare parts ceecececccecesseeeseneeeeeeneeeeeeeeeseseeeesaes 5 Functionality check 25 Certified engines 5 PC diagnostics program 25 Repair instructions a a 6 Fault detection 0 0 0 0 ccceeeeeeeeeeeeteenneeeeeeeeeee 26 Our common responsibility 6 Symptoms and possible causes seeeeeeeee 26 Tightening torques 6 Torque angle tightening 7 Diagnostic function 27 LOCK NUS U u usasqa asss ssaaska sassa kasananasana 7 The role of diagnostic function 27 Strength classes ecccceeeteeeeeeeeeeeeeteeeeeneeeeseaes 7 Diagnostic function affects the engine 27 S eala ls erer iiri seisne niin EATERS ENESE 7 Reading out error codes
32. amps and other instruments show normal function and the control is working nor mally the operator can choose to continue operating and remedy the disturbance later If the engine is swit ched off certain error codes could disappear Reading out error codes If the diagnosis button 2 is depressed and then rele ased an error code blinks out 1 The error code consists of two groups of blinks sepa rated by a two second pause The error code is read by counting the number of blinks in each group Example 3 3 pause 3 3 3 3 Error code 2 4 The error code is stored and can be read as long as the disturbance remains The error code list contains information on cause response and corrective action Read out as follows 1 Press in the diagnosis button 2 2 Release the diagnosis button and note the error code that blinks out 1 3 Repeat points 1 2 A new error code blinks out if more codes are stored Repeat until the first error code reappears NOTE When the first error code reappears all error codes have been read out Erasing error codes The error code memory of the diagnostic function is reset when power to the engine is cut off NOTE The power must be completely disconnected When the power is turned on the diagnostic function checks to see if there are any disturbances in the EDC Ill system If disturbances are present new error codes are set This means that 1 Error codes for disturbances
33. arance Check that the unit injector and connection cable are not damaged Doacompression test and check cylinder 3 135 Code 7 3 Cause Unit injector cylinder 3 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check the contact pressure in sleeve 23 in the black cable glove of the engine control unit ECU Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 40 Diagnostic function 140 Code 7 4 Cause Unit injector cylinder 4 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action e Check that the wiring to the unit injectors is not damaged e Check that the connections to the unit injector are not damaged 141 Code 7 4 Cause Unit injector cylinder 4 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 142 Code 7 4 Cause Unit injector cylinder 4 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged e Check that the connections
34. at the wiring between the CIU and the engine control unit ECU is not damaged Check pin sleeve 22 and 37 in the connector on the CIU Check the contact pressure in sleeves 25 and 26 in the red cable glove of the engine control unit ECU AN IMPORTANT If error numbers 115 125 and 135 are active simulatneously check the con tact pressure in sleeve 12 in the black cable glove of the engine control unit ECU AN IMPORTANT If error numbers 145 155 and 165 are active simulateously check the contact pressure in sleeve 24 in the black cable glove of the engine control unit ECU 45 Group 23 EDC III Electronic fault detection Electronic fault detection General Check the following before starting electronic fault detection Error codes Fuel level and filter Air filter Battery Wiring visually Main switch fuses connectors Connections to relays Electronic fault detection can be performed on the fol lowing components Charge air charge pressure sensor Coolant temperature sensor Water monitor for fuel pre filter Camshaft and flywheel sensors Oil pressure temperature sensor Coolant level sensor Unit injector PC diagnostics program Starter motor Relays Generator 46 Functionality check of lines and connectors First check that the fuse is not loose Use multimeter 9510060 8 to take a reading from the wiring Connect adapter 9998505 between the engine s cable gl
35. auses of error Use the wiring diagram to check which wiring harnes ses are used for the function Begin with the most pro bable wiring harness in the circuit Check the following e Disconnect the relevant connectors from both ends of the wiring harness Measure the resistance using multimeter 9510060 8 between the ends of the line Desired value R 0 Q e Shake the line if possible and pull on the connec tions while measuring to find where the damage is If you cannot find the error check the next wiring harness following the wiring diagram Contact resistance and oxidation The resistance in the contacts lines and connections should be 0 Q There is some resistance however due to oxidation on the connections If resistance is too great there will be disturbances in the function How large resistance can be without dis turbances arising varies depending on the size of the load in the circuit Check the following e Look for oxidation which can deteriorate the con tact in the connections Check that the cable shoes are not damaged that they are correctly fitted in the connector and that the line is correctly connected to the cable shoe e Test that the sleeves provide good mechanical contact Use a loose pin to test A Important DIN contacts to pressure sensors must not be filled with grease 47 Group 23 EDC III Electronic fault detection Splicing electrical cable for cable glove Sp
36. ctly fitted in the connector and that the line is correctly connected to the cable shoe e Test that the sleeves provide good mechanical contact Use a loose pin to test A Important The cable glove of the control unit ECU should only be checked using gauge 9998482 e Carefully insert gauge 9998482 in the cable glove Move the gauge back and forth a few times until you feel that the cable glove clamps around the gauge If the cable glove does not clamp or clamps weakly the cable shoe must be replaced See Splicing electrical cable for cable glove e Filthe sleeves that have been checked with low temperature grease 1161417 9 A Important DIN contacts to pressure sensors must not be filled with grease e Check that the lines are really clamped Avoid clamping the lines too close to the contacts Fault detection on cables and connectors Visually check the connections Check the following Look for oxidation which can deteriorate the con tact in the connections Check that the cable shoes are not damaged that they are correctly fitted in the connector and that the line is correctly connected to the cable shoe e Test that the sleeves provide good mechanical contact Use a loose pin to test e Shake the line if possible and pull on the connec tions while measuring to find where the damage is Electronic fault detection Interruption Chafed or worn lines or loose connections could be possible c
37. d by the diagnostic lamp 1 which begins to blink Guidance for fault detection If the diagnosis button 2 is depressed and then released the diagnostic lamp 1 blinks out an error code The code is found in the error code list with information on cause response and corrective action The diagnostic function affects the engine in the following manner when 1 The diagnostic function has detected a minor IMEF A if d i disturbance that will not damage the engine Response The engine is not affected 2 The diagnostic function has detected a serious disturbance that will not immediately damage the engine Response TAD1240 42GE VE Engine is switched off TWD1240VE Engine is switched off or engine torque is lowered until the value is normalized 3 The diagnostic function has detected a serious disturbance that makes it impossible to control engine operation Response TAD1240 42GE VE RPM maintained TWD1240VE The engine goes to idle Idle or freezing of RPM can be set using the Volvo Penta Parameter Tool IR N If the diagnosis button s indicator blinks 1 Reduce RPM to idle 2 Press the diagnosis button 2 to acknowledge the message 3 Release the diagnosis button and note the error code that blinks out 1 See Reading out error codes 4 Look up the error code in the error code list and follow the recommended course of action 27 Group 23 EDC III NOTE If the warning l
38. damage and that such use does not result in mal function In a number of cases there may be special safety ru les and user instructions for the tools and chemicals mentioned in the Service Manual Such rules and ins tructions must always be followed and there are no special instructions for them in the Service Manual The majority of risks can be avoided by taking certain elementary precautions and using common sense A clean workplace and a clean engine eliminate many risks of injury and faulty operation It is extremely important especially in connection to work on fuel systems lubrication systems inlet sys tems turbochargers bearings and seals to keep out dirt and foreign particles of other kinds If this is not done malfunction or a shorter repair life could be the result Our common responsibility Every engine consists of numerous interacting sys tems and components The deviation of a component from its technical specification could dramatically in crease the environmental impact of an otherwise good engine It is therefore extremely important for speci fied wear tolerances to be maintained for systems with facilities for adjustment to be correctly set and for Volvo Penta Original engine spare parts to be used The intervals in the engine maintenance schedule must be followed Certain systems such as fuel system components may require special competence and special testing equipment For environmental and other
39. e not damaged Diagnostic function 151 Code 7 5 Cause Unit injector cylinder 5 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action e Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 152 Code 7 5 Cause Unit injector cylinder 5 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 153 Code 7 5 Cause Unit injector cylinder 5 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged e Check that the connections to the unit injector are not damaged 41 Group 23 EDC III 154 Code 7 5 Cause Error in compression or the unit injector on cy linder 5 Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action e Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged Doacompression test and check cylinder 5 155 Code 7 5 Cause Unit injector cylinder 5 Electronic error Response The engine runs on
40. e for any fault detection 25 Group 23 EDC III Fault detection Fault detection A number of symptoms and possible causes for engine problems are described in the table below Always contact your Volvo Penta dealer if problems occur that you are not able to solve on your own AN WARNING Read through the safety instructions for maintenance and service work in the chapter Safety in formation before starting to work Symptoms and possible causes 3 Diagnosis button s indicator is blinking See the chapter Diagnostic function The engine cannot be stopped 2 5 The starter motor does not rotate 1 2 3 4 5 6 7 8 25 The starter motor rotates slowly 1 2 The starter motor rotates normally but the engine does not start 9 10 11 12 13 The engine starts but stops again 9 10 11 12 14 The engine does not reach the correct operating speed at full throttle 10 11 12 13 14 22 26 27 28 29 The engine runs unevenly 11 12 13 High fuel consumption 13 14 16 26 Black exhaust smoke 13 14 Blue or white exhaust smoke 15 16 23 Low oil pressure 17 High coolant temperature 18 19 20 21 Low coolant temperature 21 No or poor charging 2 24 Discharged batteries 11 Air in fuel system 20 Faulty circulation pump Poorcontact interruption on 12 Water contaminatesinthe fuel 21 Defective thermostat Beene 13 Faulty unit injectors 22 Cloggedintercooler EN EECH
41. e sensor Check that the 23 pin connector is fitted correctly Check pin C and sleeve C in the 23 pin connector Check the contact pressure in sleeve 3 in the red cable glove of the engine control unit ECU 30 Diagnostic function 24 Code 2 7 Cause RPM potentiometer connected to the engine control unit ECU Short to negative Response The engine goes to idle If the pedal is re leased and then depressed again the engine can limp home using the idle contact Corrective action e Check that the potentiometer is connected cor rectly Check that the wiring to the potentiometer is not damaged Check the function of the potentiometer 21 Code 2 8 Cause RPM potentiometer connected to CIU Short to negative Response The engine goes to idle If the pedal is re leased and then depressed again the engine can limp home using the idle contact Corrective action Check that the potentiometer is connected cor rectly Check that the wiring to the potentiometer is not damaged e Check the function of the potentiometer 22 Code 2 8 Cause RPM potentiometer connected to CIU Interrupted or shorted to positive Response The engine goes to idle If the pedal is re leased and then depressed again the engine can limp home using the idle contact Corrective action Check that the potentiometer is connected cor rectly Check that the wiring to the potentiome
42. e voltage should be about 0 5 V Checking the function of oil temperature 1 Disconnect the connector from the oil pressure sensor 2 Connect 4 pin adapter 9998534 between the sensor connector and multimeter 9510060 8 3 Measure with the multimeter set to measure resis tance between the measurement points of the adapter The multimeter should show the following values Measurement points Desired values 34 R 1 9 kQ 20 C 68 F 34 R 0 1 KQ 100 C 212 F NOTE Even if resistance values follow those in the above table it is no guarantee that the sensor is fault free 51 Group 23 EDC III Fault detection on unit injectors Error symptoms The engine runs unevenly or has decreased perfor mance Error causes The above error symptoms can have several causes False sensor signals Worn piston rings Clogged air filter Poor quality fuel Water in fuel Air in fuel High exhaust counterpressure Clogged fuel system Low fuel pressure Incorrect valve clearance Defective unit injector Incipient shearing breakdown Determine or rule out error causes using the PC diagnostics program NOTE Read the instructions in the user manual for the PC diagnostics program before each test 1 Perform a relative compression test on the cylin ders Read the bar graph in the program One or more bars will be at 100 If any of the bars show a va lue lower than 80 relative compression there is probably a com
43. ecial tools 951 2636 9999324 Repair kit 1078054 1 Disconnect the cable glove from the control module See Control module replacement Remove the cable glove in such a way that the cable to the pin that is to be replaced is accessible 2 Remove the pin using tool 9992636 or a very small instrument screwdriver 9512636 NOTE Remove only one pin at a time 3 Clip off the electrical cable at the pin that is to be replaced Splice the new one using repair kit 1078054 Use cable shoe pliers 9999324 4 Carefully warm the splice with a hot air gun so that the insulation shrinks and forms a seal 5 If replacing several pins put the first pin back into the correct spot in the cable glove before remo ving the next pin Check that the pin s lock catch securely locks the pin in the cable glove 6 Attach the electrical cables with insulation and cable tie in the cable glove in reverse order from removal Refit the cable glove in reverse order from removal Make sure that the cable glove and the connection to the control module are clean and dry 9 Fit the cable glove to the control module See Control module replacement 10 Start the engine and check that no error codes arise 48 Group 23 EDC Ill Checking the combined sensor for charge air pressure temperature Checking charge air pressure 1 Switch off the engine 2 Disconnect the connector from the charge air pressure sensor and connect
44. eck that the slip rings are not burned or otherwise damaged Overload test on rotor 1 2 Set the multimeter for diode measurement Connect the test probes between the stator body and one of the three stator windings The instrument should read OL If any other value is shown the stator is short cir cuited Electronic fault detection 61 Group 23 EDC III Electrical system Electrical system Important about the electrical system AN Important Stop the engine and cut off the po wer with the main switch before working with the electrical system 1 Main switch Never open the circuit between the generator and the batteries when the engine is running The main switch switches must never be swit ched off before the engine has stopped If the circuit is opened when the engine is running the voltage regulator can be ruined and the gene rator can be badly damaged For the same reason charging circuits must not be switched when the engine is running For si multaneous charging of two independent battery circuits a Volvo Penta charge distributor can be mounted on the standard generator accessory 2 Batteries Never mistake the positive and negative poles for each other when installing the batteries This could cause serious damage to the electrical equipment Compare with the wiring diagram Battery poles should be well cleaned a
45. eck that the wiring to the unit injector is not da maged Check that the connection to the unit injector is not damaged Group 23 EDC Ill 164 Code 7 6 Cause Error in compression or the unit injector on cy linder 6 Response Cylinder balance is adversely affected gt Uneven running at low RPM and low load Corrective action Check the fuel feed pressure Check the valve clearance Check the unit injector and the connection cable e Do a compression test and check cylinder 6 165 Code 7 6 Cause Unit injector cylinder 6 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check the contact pressure in sleeve 35 in the black cable glove of the engine control unit ECU Check that the wiring to the unit injector is not da maged Check that the connection to the unit injector is not damaged 82 Code 9 8 Cause EEPROM error CIU Response CIU returns to factory settings Corrective action Replace the CIU unit 212 Code 9 8 Cause Flash memory error CIU Response The engine goes to idle Corrective action Replace the CIU unit Diagnostic function 254 Code 9 8 Cause Controller failure CIU Response The engine cannot be started if the engi ne is running gt Idle Corrective action Replace the CIU unit 255 Code 9 9 Cause Memory error in the engine control module EMS Response T
46. ectronic Diesel Control is an electronic system with CAN communication for diesel engine manage ment The system is developed by Volvo Penta and covers fuel management diagnostic function etc The sys tem consists of a control module six unit injectors a number of sensors that provide information to the control module and a data link connector for diagnostics and functionality checks The EDC III system also has a stand alone interface that can be linked directly to the engine control module on the engine The engine can be linked to a CAN interface and a Control Interface Unit CIU which is an interface to the operator area Control module The EDC III system processor is located in the con trol module protected from moisture and vibrations The processor continually receives information regar ding e Engine speed Charge air pressure Charge air temperature Coolant temperature Oil pressure Oil temperature Fuel alarm combined alarm for water in fuel and fuel pressure e Coolant level This information is used to make exact determinations on current operating conditions and allows the proces sor to calculate the correct amount of fuel check the condition of the engine etc 12 Fuel management The engine s fuel need is analyzed up to 100 times per second depending on engine speed The quantity and timing of fuel injection into the engine are control led completely electronically via fu
47. ed for national and regional environ mental legislation the manufacturer undertakes to en sure that the environmental requirements are fulfilled both in new engines and those already in use The product must correspond to the specimen product that was approved for certification For Volvo Penta as the manufacturer to be answerable for ensuring that engi nes in use meet the stipulated environmental require ments the following requirements as regards service and spare parts must be fulfilled e The service intervals and maintenance measures recommended by Volvo Penta must be followed Only Volvo Penta Original Spare Parts intended for the certified engine version may be used Service involving injection pumps pump settings or unit injectors must always be performed by an authorized Volvo Penta workshop The engine must not be rebuilt or modified in any way except with accessories and service kits that Volvo Penta has developed for the engine in question Installation changes to exhaust pipes and supply air ducts for the engine compartment ventilation ducts must not be made indiscriminately as this could affect exhaust emissions Any security seals must not be broken by non authorized personnel AN IMPORTANT When spare parts are required use only Volvo Penta Original Spare Parts If non original spare parts are used AB Vol vo Penta will no longer be responsible for ensuring that the engine corresponds to the cert
48. ed on the bottom of the fuel pre filter Its role is to guard against water in the fuel system The monitor consists of two copper pins between which resistance is measured When resistance falls below the limit value which indicates that there is wa ter in the fuel a warning signal is sent to the control module Tachometer sensor camshaft 2 The tachometer sensor is located on the upper timing cover The tachometer sensor which is linked to the camshaft is an inductive sensor It reads a toothed wheel with seven pins The impulses from the cams haft sensor provide the control module information on which cylinder is next in line for injection and when it receives it Oil pressure temperature sensor 10 Oil pressure and oil temperature are measured by a combined sensor that is located on the left hand side of the engine next to the control module The sensor is mounted in the engine block so that measurement is taken from the oil system s main channel The sensor consists of a non linear resistor whose resistance is dependant on the temperature of the resistor body Resistance decreases as tempera ture increases The pressure signal is a voltage signal proportional to the pressure The reference voltage for the sensor is 5 Volts 14 Group 23 EDC III Tachometer sensor flywheel 18 This sensor is located on the left hand side of the fly wheel housing The tachometer sensor on the flywheel is an ind
49. el valves on the unit injectors This means that the engine always receives the cor rect amount of fuel under all operating conditions providing benefits including improved fuel economy and minimized exhaust emissions 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 ang le This control is done primarily with the help of the tachometer sensors and the combined sensor for charge air pressure temperature The control module actuates the unit injectors via an electronic signal to the unit injectors electromagneti cally controlled fuel valve which can then be opened or closed When the fuel valve is open fuel streams by through the unit injector holes and out through the fuel chan nel Fuel is not injected into the cylinder at this stage When the fuel valve is closed pressure is built up by the mechanically driven pump piston of the unit injec tor Once enough pressure is built up fuel is injected into the cylinder via the injector portion The fuel valve is reopened and pressure in the unit in jector sinks while fuel injection to the cylinder ceases To determine when the fuel valve should be opened or closed the control module has access to signals from sensors and switches Group 23 EDC III Calculation of fuel quantity The amount of fuel injected into a cylinder is calcula ted by the control mod
50. emperature When measuring in the lower tempera ture interval 0 40 C 32 104 F holding the sensor in your hand is sufficient to make the value quickly go to the lower resistance value 49 Group 23 EDC III Checking water monitor fuel pre filter 1 Red cable in connector 2 Yellow cable in connector 3 Black cable in connector 1 Disconnect the connector and remove the water monitor from the fuel pre filter 2 Connect the red cable 1 to a 24V power source Connect a light bulb 1W between the yellow ca ble 2 in the connector and a 24V power source Connect the black cable 3 in the connector to ground 3 Submerge the sensor s contact pins in a bowl of water The light bulb should light when the water is between the sensor s contact pins 4 When the sensor is removed from the water the light bulb should go out 50 Electronic fault detection Checking the camshaft and flywheel sensors The tachometer sensors for the camshaft and the fly wheel are identical For a visual check first remove the sensors from the engine Then disconnect the connector and check that the sensors are not dama ged and that no debris has fastened on the sensors An induction test is performed as follows 1 Set multimeter 9510060 8 to measure resistance Use the multimeter to measure on the connector pins Resistance should lie between 775 945 Q 2 Quickly pass a metal object close to the senso
51. emperature sensor is fitted correctly Check the function of the charge air temperature sensor 27 Code 3 3 Cause Coolant temperature sensor Interrupted or shorted to positive Response Preheating is activated even if the engine is warm Corrective action Check that the connector of the coolant tempera ture sensor is fitted correctly Check that the wiring to the coolant temperature sensor is not damaged Check that the coolant temperature sensor is fit ted correctly Check the function of the coolant temperature sensor 28 Code 3 3 Cause 1 Coolant temperature sensor Short to negati ve Response Preheating is activated even if the engine is warm Corrective action Check that the wiring to the coolant temperature sensor is not damaged Check that the coolant temperature sensor is fit ted correctly Check the function of the coolant temperature sensor 31 Group 23 EDC III 67 Code 3 4 Cause Charge air pressure sensor Short to positive Response The engine smokes more than it usually does when accelerating under loading Corrective action Check that the wiring to the charge air pressure sensor is not damaged Check the function of the charge air pressure sen sor 68 Code 3 4 Cause 1 Charge air pressure sensor Interrupted or shorted to negative Response The engine smokes more than it usually does when accelerating under loading
52. erally required one to handle the lifting device and the other to make sure that the components go cle ar and are not damaged when lifting Always ensure in advance that there is suffi cient space for dismantling to be done without risk of injury or material damage WARNING Electrical system and fuel system components of Volvo Penta products are desig ned and manufactured to minimize the risk of explosion and fire The engine must not be run in environments in which they will be surrounded by explosive media Always use fuel recommended by Volvo Penta See the Owner s Manual Use of a lower grade fuel could damage the engine On a diesel engi ne a poor grade of fuel could lead to overrev ving of the engine causing risk of injury and da mage Poor fuel can also give rise to higher maintenance costs Bear in mind the following when cleaning with high pressure equipment never direct the jet of water on seals rubber hoses electrical compo nents or the radiator Always use protective goggles when performing work in which splinters grinding sparks and splashes of acid or other chemicals could occur The eyes are especially sensitive and an injury could result in loss of sight Avoid getting oil on your skin Prolonged or re curring contact with oil can damage the skin re sulting in irritation dehydration eczema and other skin disorders From a hygienic point of view used oil is more harmful than fresh oil Wear pr
53. essure cap on the expansion tank Check the function of the coolant temperature sensor Check the function of the thermostat 60 Code 6 2 Cause Intake air temperature is too high Response Engine output is limited to 50 if this protective feature has not been disabled by the para meter setting tool Corrective action e Check the coolant level Check the intercooler cleanness Check the function of the charge air temperature sensor Check the function of the thermostat 213 Code 6 4 Cause Datalink CAN error CIU Response Instruments and alarm lamps stop working Corrective action Check that the 8 pin connector is not damaged Check that the wiring between the CIU and the engine control unit ECU is not damaged e Check that sleeves 11 and 12 in the CIU connec tor are not damaged Check the contact pressure in sleeves 1 and 2 in the red cable glove of the engine control unit ECU Group 23 EDC Ill 38 Code 6 5 Cause Datalink CAN error engine control module EMS Response Engine not running the engine cannot be started Engine running engine goes to idle and can only be stopped using the emergency stop Corrective action e Check that the 8 pin connector is not damaged Check that the wiring between the CIU and the engine control unit ECU is not damaged e Check that sleeves 11 and 12 in the CIU connec tor are not damaged Check the contact pressure in sle
54. eves 1 and 2 in the red cable glove of the engine control unit ECU 105 Code 6 5 Cause Datalink error CAN Response Engine not running gt The engine cannot be started Engine running gt Engine goes to idle and can only be stopped with the emergency stop Corrective action Check that the 8 pin connector is not damaged Check that the wiring between the CIU and the engine control unit ECU is not damaged e Check that sleeves 11 and 12 in the CIU connec tor are not damaged Check the contact pressure in sleeves 1 and 2 in the red cable glove of the engine control module EMS Diagnostic function 106 Code 6 5 Cause Datalink error CAN Response Engine not running gt The engine cannot be started Engine running gt Engine goes to idle and can only be stopped with the emergency stop Corrective action e Check that the 8 pin connector is not damaged Check that the 8 pin cable between the CIU and the engine control unit ECU is not damaged e Check that sleeves 11 and 12 in the CIU connec tor are not damaged Check the contact pressure in sleeves 1 and 2 in the red cable glove of the engine control unit ECU 180 Code 6 6 Cause Oil pressure is too low Response Engine is switched off if this protective feature has not been disabled by the parameter set ting tool Alarm lamp lights Corrective action e Check the oil level e Check that the oil filter is not clogged
55. g to the alarm lamp is not damaged Check sleeve N in the 23 pin connector Check the contact pressure in sleeve 33 in the black cable glove of the engine control unit ECU 220 Code 4 3 Cause Lamp to indicate operation Interruption Response Indicator lamp does not work If the circuit is interrupted during start up diagnostics are deacti vated Corrective action Check the alarm lamp Check that the wiring to the alarm lamp is not damaged Check sleeve N in the 23 pin connector Check the contact pressure in sleeve 33 in the black connector of the engine control unit ECU Diagnostic function 221 Code 4 3 Cause Lamp to indicate operation Short to negative Response The indicator lamp shines constantly Corrective action e Check that the wiring and connection to the alarm lamp are not damaged 222 Code 4 3 Cause Lamp to indicate operation Short to positive Response Indicator lamp does not work If the circuit is interrupted during start up diagnostics are deacti vated Corrective action Check that the wiring and connection to the alarm lamp are not damaged 223 Code 4 4 Cause Overspeed alarm Circuit interruption Response Alarm lamp does not work If the circuit is interrupted during start up diagnostics are deacti vated Corrective action Check the alarm lamp Check that the wiring to the alarm lamp is not da maged Check
56. gh frequen cies Measure between pins 87 and 30 of the re lay The multimeter should not emit an alarm 3 Use the multimeter set to measure resistance Measure between pins 85 and 86 of the relay The multimeter should read 240 270 Q 4 Connect 24V between pins 85 and 86 Use the multimeter set to measure high frequencies Mea sure between pins 87 and 30 of the relay The multimeter should then emit an alarm sound 5 Connect 24V between pins 85 and 86 Use the multimeter set to measure high frequencies Mea sure between pins 87a and 30 of the relay The multimeter should not emit an alarm 6 Replace the relay if test results do not match those listed above 54 Group 23 EDC Ill Fault detection on the generator First remove the generator so that measurement points are accessible 1 Pry loose the plastic cover of the generator with a screwdriver 2 Remove the regulator s four screws Remove the bracket s two screws and remove the bracket and the regulator Electronic fault detection 55 Group 23 EDC III Carbon brushes The length of carbon brushes is measured between the contact surface and the brush holder If the size of the projecting portion is less than 0 2 or if the brushes are damaged they must be replaced NOTE When soldering make sure that the solder does not penetrate too far in the line to the brushes The line would then become stiff hindering flexibility Regulator Chec
57. gh power to rotate the engine at normal speed Checking voltage feed 1 Check that the voltage in the battery is at least 24 7V when unloaded by measuring between the battery poles with multimeter 9510060 8 2 Turn on the main switch Check that the voltage between positions 30 and 31 on the starter motor are the same as the battery Check 1 That error code 4 6 is not set 2 Thata start request is sent using the PC diagnostics program 3 That the starter motor is activated using the PC diagnostics program Carbon brushes Specifications for carbon brushes in the starter motor are described below Carbon brush appearance New 23 mm 0 91 Replace at 13 mm 0 51 Electronic fault detection 53 Group 23 EDC III Electronic fault detection Functionality check of relays Multimeter 9510060 8 is used for fault detection Two different symbols are used to represent the line connection Symbol 1 indicates an interruption or ex tremely high resistance The multimeter does not emit an alarm Symbol 2 indicates a contact or extremely low resis tance The multimeter emits an alarm Check the function of the relays as follows NOTE Disconnect the main relay from the engine be fore beginning fault detection 1 Use the multimeter set to measure high frequen cies Measure between pins 87a and 30 of the re lay The multimeter should then emit an alarm sound 2 Use the multimeter set to measure hi
58. gnal Response The engine is extremely hard to start and runs unevenly if it does Corrective action Check that the sensor connector is fitted correctly Check that the wiring to the tachometer sensor is not damaged Check that the tachometer sensor is correctly fit ted in the flywheel housing Check the function of the tachometer sensor Check the contact pressure in sleeves 30 and 31 in the black cable glove of the engine control unit ECU 18 Code 2 4 Cause RPM sensor flywheel Abnormal frequency Response The engine is extremely hard to start and runs unevenly if it does Corrective action Check that the tachometer sensor connector is fit ted correctly Check that the wiring to the tachometer sensor is not damaged Check that the tachometer sensor is correctly fit ted in the flywheel housing Check the function of the tachometer sensor 101 Code 2 4 Cause Tachometer sensor flywheel Intermittent signal Response The engine is extremely hard to start and runs unevenly if it does Corrective action Check that the tachometer sensor connector is fit ted correctly Check that the wiring to the tachometer sensor is not damaged Check that the tachometer sensor is correctly fit ted in the flywheel housing Check the function of the tachometer sensor Check the contact pressure in sleeves 30 and 31 in the black cable glove of the engine control unit ECU
59. he engine cannot be started varies Corrective action Replace the engine control module EMS 32 Code Cause Diagnostic lamp linked to the Stand Alone interface Interruption Response The diagnostic lamp does not light during a lamp test No error codes can be read out Corrective action Check that the lamp is not damaged Check that the wiring to the lamp is not damaged Check the contact pressure in sleeve J in the 23 pin connector Check the contact pressure in sleeve 21 in the red cable glove of the engine control unit ECU 33 Code Cause Diagnostic lamp linked to the Stand Alone interface Short to negative Response The diagnostic lamp shines constantly Corrective action Check that the wiring to the lamp is not damaged Check that the lamp is correctly mounted 43 Group 23 EDC III 34 Code Cause The diagnostic lamp linked to the Stand Alone interface Short to positive Response The diagnostic lamp does not light during a lamp test No error codes can be read out Corrective action Check that the wiring to the lamp is not damaged Check that the lamp is correctly mounted 57 Code Cause The charge air pressure is too high Response None Corrective action Check the function of the turbocharger Check the function of the charge air pressure sen sor Check the fuel quantity unit injector 58 Code Cause The charge air pressure
60. he engine control module EMS Response Engine will not start Corrective action Replace the engine control unit ECU Group 23 EDC Ill 187 Code Cause Memory error in the engine control module EMS Response Engine will not start Corrective action Replace the engine control unit ECU 188 Code Cause Programming plug EOL Short to positive Response Engine will not start engine control unit ECU is in programming mode Corrective action Check that the EOL contact is not strapped Check that the wiring to the EOL contact is not damaged 189 Code Cause Programming plug EOL Short to negative Response None Corrective action Check that the wiring to the EOL contact is not damaged 192 Code Cause Coolant level monitor Short to positive Response None Corrective action Check that the wiring to the coolant level monitor is not damaged Check that the coolant level monitor is fitted cor rectly Diagnostic function 231 Code Cause Input for preheating request Short to negative Response Pre heating can not be activated Corrective action e Check that the wiring and the connection to the preheating switch are not damaged 233 Code Cause Datalink error J1708 CIU Response Diagnostic codes from the engine cannot be read from the diagnostic lamp Corrective action Check that the 8 pin connector is not damaged Check th
61. heck the function of the relay Check the contact pressure in sleeve 36 in the red cable glove of the engine control unit ECU 75 Code 5 4 Cause Preheating relay Short to negative Response Preheating is constantly activated Corrective action Check that the wiring to the input on the relay is not damaged Check the function of the relay 76 Code 5 4 Cause Preheating relay Short to positive Response Preheating cannot be activated Corrective action Check that the wiring to the input on the relay is not damaged Check the function of the relay 183 Code 5 8 Cause Oil temperature is too high Response Limited engine output if this protective feature has not been disabled by the parameter set ting tool Alarm lamp lights Corrective action Check the oil level Check the oil temperature Check the oil system thermostat Check the function of the oil temperature sensor 36 Diagnostic function 31 Code 6 1 Cause High coolant temperature Response TAD1240 42GE Limited engine output if this protective feature has not been disabled by the parameter setting tool Alarm lamp lights TWD1240VE Engine is switched off if this protective feature has not been disabled by the parameter set ting tool Alarm indicator lights Corrective action Check the coolant level Check the intercooler cleanness Check to see if there is air in the coolant system Check the pr
62. ified version Any injury damage or cost arising due to the use of non original spare parts for the product in question will not be covered under the terms of warranty as undertaken by Volvo Penta Group 23 EDC III Repair instructions Repair instructions The work methods described in the Service Manual apply to a workshop environment The engine is there fore lifted out of place and mounted on an engine stand Unless otherwise stated reconditioning work that does not require the engine to be removed can be performed in situ using the same work methods See the Safety information chapter for a closer ex planation of the warning symbols found in the Service Manual N WARNING Z IMPORTANT NOTE are by no means all embracing as we cannot of cour se foresee everything that could happen as service work is performed under the most widely varying con ditions So we can only point out the risks we feel could arise as a result of incorrect handling when wor king in a well equipped workshop using methods and tools that have been tested by us All work operations for which there are Volvo Penta special tools are described in the Service Manual using these tools Special tools have been developed to ensure as safe and efficient methods of working as possible It is therefore the obligation of anyone using tools or work methods other than those recommended by us to ensure that there is no risk of injury or materi al
63. in details may not be completely accurate in a number of cases The repair methods however are essentially the same The engine designation and number are given on the type plate see Technical data TAD1240GE TAD1241GE VE TAD1242GE VE and TWD1240VE The engine designation and number should always be quoted in all correspondence concerning any of the eng ines The Service Manual is primarily produced for Volvo Penta s service workshops and their qualified person nel It is therefore assumed that persons using the manual have the necessary basic knowledge and can perform work of a mechanical electrical nature that oc curs in their profession Volvo Penta is continuously developing its products and we therefore reserve the right to introduce chan ges and modifications All the information in this ma nual is based on product data available up to the time of printing Any vitally important changes to the pro duct or service methods that are introduced after that date are announced in the form of Service Bulletins Spare parts Spare parts for the electrical and fuel systems are subject to different national safety requirements Vol vo Penta Original Spare Parts meet these require ments Any type of damage occurring as a result of using non original Volvo Penta spare parts for the pro duct in question will not be covered under the terms of the warranty as undertaken by Volvo Penta Certified engines For engines certifi
64. it the new control unit Connect the cable glove to the control unit When connecting the cable glove 2 to the control unit make sure that the safety catch 1 is set Fit the cooling coil and fuel line clamps to the control unit NOTE The retaining bolts of the fuel cooling coil are self tapping as there are no threads in the control unit 9 Start the engine and perform leakage and functionality checks Repair instructions 23 Group 23 EDC III Repair instructions Start with booster batteries N WARNING Be sure to have good ventilation The batteries build oxyhydrogen gas which is very flammable and explosive A short circuit open flame or spark could cause an explosion A WARNING Never confuse the position of the cables on the battery Confusing battery poles when jumpstarting with battery cables causes short circuits and sparks which can cause ex plosion and greatly damage electrical engine components 1 Check that the voltage of the booster battery is the same as the engine s system voltage 2 First connect the red jumper cable to the positive pole of the discharged batteries and then to the positive pole of the booster battery 3 Then connect the black jumper cable to the negative pole of the booster battery anda spot a bit away from the negative pole of the discharged batteries such as by the negative lead s connection to the starter motor ZX WARNING
65. ition key start but ton is not damaged e Check the contact pressure in sleeve E in the 23 pin connector Check the contact pressure in sleeve 17 in the connector on the engine Group 23 EDC Ill 109 Code 4 8 Cause Stop input engine control unit ECU Short to negative Response The engine can only be stopped using the emergency stop on the engine Corrective action e Check that the wiring to the ignition key start but ton is not damaged Check the contact pressure in sleeve H in the 23 pin connector e Checkthe contact pressure in sleeve 6 in the con nector on the engine 43 Code 5 1 Cause Main relay Short to positive Response The instrument panel loses power when the key is twisted to start position The engine will not start Corrective action Check that the wiring to the relay is not damaged Check the function of the relay 208 Code 5 2 Cause Start input on CIU Short to negative Response The engine cannot be started Corrective action e Check that the connections to the ignition key are not damaged Check that the wiring to the ignition key is not damaged 210 Code 5 2 Cause Start input on CIU Short to positive or activated too long Response The engine starts immediately when the ignition is turned on Corrective action Check that the connections to the ignition key are not damaged Check that the wiring to the ignition key is not
66. king the regulator 1 Measure with a multimeter set for diode measure ment 2 Connect the probes between the carbon brushes 3 Switch the probes 4 Check that there is no short circuit NOTE If you suspect a regulator error it is best to fit a new regulator on the generator and test run the char ging system 56 Electronic fault detection Group 23 EDC Ill Electronic fault detection Checking positive output diodes 1 2 Set the multimeter for diode measurement Connect the negative test probe to B and the po sitive test probe to each of the three stator win dings Take readings of the three stator windings Switch the test probes and take three more readings One time the instrument should read 400 1200mV conducting direction The other time it should read OL The diodes obstruct NOTE The entire diode package is insulated from the body of the generator d est LATE 57 Group 23 EDC III Checking negative output diodes 1 2 Set the multimeter for diode measurement Connect the negative test probe to B and the po sitive test probe to each of the three stator win dings Take readings of the three stator windings Switch the test probes and take three more readings One time the instrument should read 400 1200mV conducting direction The other time it should read OL The diodes obstruct NO
67. lvo Penta Idle 0 7 bar 10 2 psi For oil pressure 0 3 bar 4 4 psi lower than alarm value gt 1500 RPM 2 5 bar For oil pressure 0 3 bar 4 4 psi 36 3 psi lower than alarm value See diagram Oil pressure below NOTE Engine protection can be switched off Oil temperature Standard value Volvo Penta 125 C 257 F 127 C 261 F Parameter setting can be set by the customer 120 130 C 248 266 F 2 C 36 F over alarm value NOTE Engine protection can be switched off Fuel pressure Standard value Volvo Penta lt 2 bar lt 29 psi Engine not switched off Monitor water in fuel Alarm lamp lights 3 3 Oil pressure 2 3 of r z A Engine is switched off SS IM IO 150 200d 2000 rpm 20 Group 23 EDC III Limp home values emergency control values The control unit uses these bases value to be able to run the engine if a technical error arises in the system or its peripheral equipment sensors etc The following values Limp home values are stored in the control unit Charge air temperature Coolant temperature Charge air pressure Engine speed TAD1240 42GE VE TWD1240VE 3 0 2 5 bar 45 C 113 F 15 C 5 F See diagram below RPM frozen Idle Charge air pressure 500 1000 rpm 1500 2000 2500 Limit values 21 Group 23 EDC Ill Repair instructions Repair instructions When working with EDC III Follow the ins
68. n explosion in the intake manifold Danger of injury N Start the engine in well ventilated areas only If the engine is running in a confined space ex haust gases and crankcase gases should be conducted away from the engine compartment or workshop area N Avoid opening the coolant filler cap when the engine is still hot Steam or hot coolant could squirt out while the built up pressure is lost If necessary open the filler cap slowly and relea se pressure in the cooling system Be extremely carelul if a cock plug or coolant line must be removed while the engine is still hot Steam or hot coolant could squirt out in an unexpected di rection A Hot oil can cause burns Avoid getting hot oil on your skin Make sure that the lubricating system is depressurized before starting any work on it Never start or run the engine with the oil filler cap removed as oil under pressure could then escape N Stop the engine before doing any work on the cooling system Group 23 EDC III A A gt If other equipment connected to the engine changes its center of gravity special lifting devi ces may be needed to obtain the right balance and ensure safe handling Never perform any work on an engine that is suspended solely from a lifting device Never work alone when heavy components are to be removed even if a safe lifting device such as a lockable block and tackle is used Even if a lifting device is used two people are gen
69. nd cable shoes should al ways be secured and well greased Avoid quick charging the batteries If quick char ging must be used the ordinary battery cables must first be disconnected NOTE Follow applicable safety regulations when charging the batteries When charging the cell plugs should be loosened but remain in the cell hole Ventilate well especially if the batteries are being charged in a confined area Never cut off the charging current before disconnec ting the charge clamps A Warning The battery compartment must never be exposed to open flames or electric sparks Never smoke near the batteries When the bat teries are being charged they give off hydrogen which when mixed with air forms oxyhydrogen gas This gas is highly flammable and very ex plosive Always wear protective goggles when charging andhandling batteries The battery electrolyte contains highly corrosive sulfu ric acid If it gets on your skin wash the area with soap and plenty of water If the electrolyte gets in your eyes rinse them at once with plenty of cold water and seek medical attention immediately 62 3 See Start with booster batteries on how to jump start using booster batteries 4 Connecting extra equipment All extra equipment must be connected to a sepa rate junction box and fused Extra outlets directly from the instrument boards should be avoided Extra outlets are permissible only up to a max total of 5A
70. ngine 12 Swept volume liter 4 Generation 0 Version G Gen Set engine V Stationary and mobile operation E Emissions check Group 23 EDC III Tools Tools Special tools The following special tools are used when working with the engine Special tools can be ordered from AB Volvo Penta using the given number 874427 885337 951 2636 999 8482 999 8534 999 9324 951 0060 774 1383 Tool Name use 874427 T coupling diagnostic 9999324 Cable shoe pliers repair 885337 Cable PC diagnostics program 9510060 Multimeter fault detection check 9512636 Pin tool connector 7741383 CD parameter setting tool 9998482 Gauge connector 9998505 36 pin adapter diagnostics 999 8534 4 pin adapter diagnostics Group 23 EDC III Technical data Technical data Control unit VONAGE Z ua A E T NT 24V Ee 2 x 36 pin Water monitor fuel pre filter Kee E 24 V EIDEL 3 pin GOMACTLY EE Closed in the presence of water Monitor fuel pressure VONAGE uu uaaasuyasuyusakassswayausqikppawanaquibusuyakuyadkytusa 24 V ERT 2 pin Work area pressure a 0 217 5 psi 0 15 BAR Contact ype iesirea innnan siena Closed upon low fuel pressure Camshaft sensor flywheel sensor Inductive sensor Connector 2 pin Combinedsensor oilpressure temperature EE EE 5V CONMOCION ulaqa lugu us eaa 4 pin Work area pressure 0 101 5 psi 0 7 BAR
71. ns highly corrosive sulfuric acid If it gets on your skin wash the area with soap and plenty of water If the electrolyte gets in your eyes rinse them at once with plenty of cold wa ter and seek medical attention immediately Stop the engine and cut off the current with the main switch or switches before starting work on the electrical system A A The engine should be switched off when adjus ting the clutch Use the lifting eyes mounted on the engine when lifting it Always check that all lifting equipment is in good condition and that it has the right capacity for the job engine weight plus transmission and extra equipment if any To ensure safe handling and avoid damaging components mounted on the top of the engine it should be lifted using an adjustable lifting beam or one adapted to the engine All chains or cables should run parallel to each other and as perpendi cular as possible to the top of the engine 2001 AB VOLVO PENTA We reserve the right to make modifications Printed on environmentally friendly paper Group 23 EDC III General information General information About the Service Manual This Service Manual contains descriptions and repair instructions for the standard versions of the TAD1240GE TAD1241GE VE TA1242GE VE and TWD1240VE engines The Service Manual may show work operations perfor med on any of the engines listed above Consequently the illustrations and photographs showing certa
72. nssaid Wo MoT sonsoubeig guos doe yoejuoo Bulyeauaid JOBIUOD a yORUOD Jupe yoejuod dooiq Jayawonuayjod Wd Q c 0 GG S oo vv eV Ch Lt OV GE EIS LE TANTO O ODOC Q G 0 O ODOTA FOO Q N Q N GQ G G co 6 oo oi o uid z BelloA uut 1s s A rZ SAOVZLOML Lan an D bei loss e B5ueiO HO MO A Ap D HUE IUM M uaa NO POA OA Umoq woq NgI weld gS UuUMOIQ Ng psy H ongf e Wda d eng id w S1O O9 jqe SL ou A H aL Pay eh ou Sp EE BIPSVH Oh neren i EH BR o as n EE ia m EF E 67 Group 23 EDC III Electrical system Cable colors Wiring diagram Control BL Blue P Pink Interface Unit CIU LBL Lightblue R Red 1 Key breaker operating power BN Brown SB Black 15 LBN Lightbrown VO Violet 2 RPM potentiometer GN Green W White 3 Tachometer code 14 GR Gray Y Yellow 4 Oil pressure instrument OR Orange 5 Oil temperature instrument 6 Coolant temperature instrument 7 Instr
73. ntrol unit that handles all interaction with the operator It communicates with the engine over two serial com munication buses J1939 is used for controlling and monitoring the engine J1587 is used for diagnostics and backup The CIU loads a number of switches and speed re quests and forwards them to the engine It also con trols four analogue instruments and up to nine warning lamps Using a diagnosis button and diagnostic lamp the operator can read out error codes from the system 16 Design and operation Group 23 EDC III Unit injectors 20 The unit injectors are located under the valve cover mounted in the cylinder head The engine s fuel need is analyzed up to 100 times per second depending on engine speed The quantity and timing of fuel injection into the engine are control led completely electronically via the unit injectors electromagnetically operated fuel valves This means that the engine always receives the correct amount of fuel under all operating conditions providing benefits including improved fuel economy and minimized ex haust emissions Generator 8 The belt driven generator is located on the left hand front edge of the engine The voltage regulator of the generator is equipped with a sensor system The sensor system compares the charging voltage between the generator connections B and B with the actual voltage between the positi ve and negative poles of the batteries
74. on cy linder 1 Response Cylinder balance is adversely affected gt Uneven running at low RPM and low load Corrective action Check the fuel feed pressure Check the valve clearance Check that the unit injector and connection cable are not damaged e Doacompression test and check cylinder 1 38 Diagnostic function 115 Code 7 1 Cause Unit injector cylinder 1 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check the contact pressure in sleeve 11 in the black cable glove of the engine control unit ECU Check that the wiring to the unit injectors is not damaged e Check that the connections to the unit injector are not damaged 120 Code 7 2 Cause Unit injector cylinder 2 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 121 Code 7 2 Cause Unit injector cylinder 2 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 122 Code 7 2 Cause Unit injector cylinder 2 Electronic error Response
75. onic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action e Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 131 Code 7 3 Cause Unit injector cylinder 3 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 132 Code 7 3 Cause Unit injector cylinder 3 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action Check that the wiring to the unit injectors is not damaged e Check that the connections to the unit injector are not damaged 39 Group 23 EDC III 133 Code 7 3 Cause Unit injector cylinder 3 Electronic error Response The engine runs on 5 cylinders sounds uneven and has decreased performance Corrective action e Check that the wiring to the unit injectors is not damaged Check that the connections to the unit injector are not damaged 134 Code 7 3 Cause Error in compression or the unit injector on cy linder 3 Response Cylinder balance is adversely affected gt Uneven running at low RPM and low load Corrective action Check the fuel feed pressure e Check the valve cle
76. otective gloves and avoid clothes and rags ingrained with oil Wash regularly particu larly before mealtimes Use skin lotion intended for this purpose to avoid dehydration and facili tate cleansing of the skin Safety information A Most chemicals intended for the product such as engine and transmission oils glycol gasoline and diesel oil or chemicals for workshop use such as degreasers paints and solvents are injurious to health Read the instructions on the package carefully Always follow prescribed sa fety rules such as the use of respirators pro tective goggles gloves etc Make sure that other personnel are not unknowingly exposed to substances that are injurious to health such as through the air they breathe Make provision for good ventilation Deal with used and surplus chemicals in the prescribed manner Exercise great care when detecting leaks in the fuel system and testing fuel nozzles Wear pro tective goggles The jets from a fuel nozzle are under very high pressure and have great pene trative power the fuel can penetrate deep into body tissues and cause serious injury Risk of blood poisoning All fuels and many chemicals are flammable Make sure that they cannot be ignited by an open flame or spark Gasoline certain dilutants and hydrogen from batteries when mixed with air in the right proportions are highly flammable and explosive No smoking Provide for adequa te ventilation and take the nece
77. ove and the control unit ECU Use the wiring diagram to check that you are taking a reading from the correct spot Use multimeter 9510060 8 to take the reading NOTE Never take a reading by puncturing the insulation Check the reading value with that which is noted in the wiring diagram If the reading can not be determined from the wiring diagram check the lines separately Tool 9998534 should always be used when taking a reading from a 4 pin connector of type DIN contact Contact problems Defective contacts or occasional recurring errors could be difficult to detect and arise often from oxida tion vibrations or poorly connected lines Wear can also cause errors Avoid disconnecting a connector unless absolutely necessary Other contact problems can arise such as through damaged pins sleeves or connectors Shake the line and pull on the connections while mea suring to find where the line is damaged The resistance in the contacts lines and connections should be 0 Ohm There is some resistance however due to oxidation on the connections If resistance is too great there will be disturbances in the function How large resistance can be without dis turbances arising varies depending on the size of the load in the circuit Group 23 EDC Ill Check the following Look for oxidation which can deteriorate the contact in the connections Check that the cable shoes are not damaged that they are corre
78. pression error Perform the test th ree times If compression is within the limit values 80 100 continue with the next point There is a risk that all cylinders have poor compression 2 Perform an injector test Switch off one injector at a time When a functional injector is switched off the noise level of the engine will change If that does not happen there is probably an injector error 3 Performa relative acceleration test Bear in mind that high engine speed gives inaccurate measure ment results Lower the engine speed when mea suring The test will calculate the average value of the relative cylinder acceleration from all cylin ders If the results from one cylinder differs from the other it is probably an injector error ora symptom of poor compression 52 Electronic fault detection E lsaxr 5 bh fara Ir Hert Rinri ri Lumas Fr hcuka AAG r EF Tara Wal eae Dsg abel 8 Fr ZK Do mat crank the engine Catrelon onions ce or L ai Lib Ver dei zu Hay ECH Hexe biter Enie E orn Legg Febrer oo Laveposcen Tedre Wa beat peeked DE ma Srp val ee Bh eg KI al BR lt s oi oj fon HIRT IER ban eae F r m DI r KI Ed s ku D i w Group 23 EDC III Fault detection on starter motor and lines General If the voltage level of the battery is under 24 7V as measured from the battery the starter motor does not have enou
79. put without fan IMQQTAKT ENGINE IKFOPMATIOR VOLVO PENTA AB Mat en Panta Sweoen ne min KE e pispcacemeaTs J ament IF Q Ej m awe WODEL A EXNAUST wg Em LP T TO rom aart LI CONSTANT SPEED Ou ENGINE CODE POWER FUE BATE gut TINING LOW 11 SPEED 3 DS Am WE de S be T DE BG D G DIRECTIVE 41068 FC APPROYA Ne i 1 1 oll Le Eu TH 5 ENGIKE CO4FORMS 19 SIAGE OF Taz vr ROAD MOB LL MACHIAERT DIRECT It Computer kit number B C Max rom D E Product number RATED POWER CET RATED SPEED E J DATASET CD US4 THIS ENGINE CORFORMS 10 1994 U S EPA REGJ ATICHS LARGE NGH 3DAD COMPRESS H IGM TION EHG1NES THIS ENGIKE 13 CERTIFIED Th OPERATE OH GIESE FUE CNLY SFEC WO EE ECU BATCH BEE ECU CALIFORNIA THES ENGINE CONFORMS TO 1548 U S EPA elle FOR AAT DUTT OFF ROAD DIESEL CYL ENGIRES AS APPLICABLE The above plate shows K Engine family J Swept volume A Engine designation F1 Valve clearance inlet F2 Valve clearance outlet l Emission Control devices P Only constant RPM E Part number decal B Engine code in engine family C Output RPM D Fuel quantity M H Certification approval number EU Engine speed Explanation of engine designation Ex TAD1240GE TWD1240VE T Turbo A Air to air Charge air cooler W Water to air intercooler D Diesel e
80. r Check that the multimeter gives a reading When replacing and fitting a sensor make sure that any adjusting shims are refitted 3 Check that the sensor is securely mounted and that the distance between sensor and wheel is correct Sensor Distance Flywheel 0 75 2 1 mm 0 03 0 83 Camshaft 0 3 1 0 mm 0 012 0 039 NOTE For adjustment of the sense clearence plea se see Workshop Manual Group 21 Group 23 EDC Ill Electronic fault detection Checking the combined sensor Checking the coolant level for oil pressure temperature sensor Checking the function of oil pressure 1 Empty the coolant from the expansion tank 1 Switch off the engine i AN Warning NEVER open the expansion tank s 2 Disconnect the connector from the oil pressure pressure cap when the engine is warm Hot Coo sensor and connect 4 pin adapter 9998534 bet lant could spray out causing burns ween the sensor connector and the engine wiring Then connect multimeter 9510060 8 between me 2 Disconnect the connector from the coolant asurement points 1 4 sensor 3 Switch on the operating voltage 3 Check that the contact is activated and sends 4 Measure using a multimeter set to measure volta a signal when the expansion tank is empty ge Check that the multimeter reads 5 0 volts 4 Then fill the expansion tank with coolant and 5 Then connect the multimeter between measure check that resistance remains the same ment points 2 4 Th
81. r 4 4 psi lower than alarm value gt 1500 RPM 2 5bar For oil pressure 0 3 bar 4 4 psi 36 3 psi lower than alarm value NOTE Engine protection can be switched off Oil temperature Standard value Volvo Penta 125 C 257 F 127 C 261 F Parameter setting can be set by customer 120 130 C 248 266 F 2 C 36 F over alarm value NOTE Engine protection can be switched off Fuel pressure Standard value Volvo Penta lt 2 bar lt 29 psi Engine not switched off Monitor water in fuel Alarm lamp lights RPM Standard value Volvo Penta Max operational RPM 20 Activates upon operational RPM 15 Parameter setting can be set by customer Max operational RPM 10 20 NOTE Engine protection is switched off as standard Group 23 EDC III Gransvarden Limit values electronic control unit ECU TWD1240VE Alarm limits Coolant temperature Alarm lamp lights Engine is switched off Engine output 50 Standard value Volvo Penta 98 C 208 F 100 C 212 F Parameter setting can be set by the customer 95 101 C 203 214 F 2 C 36 F over the alarm value NOTE Engine protection can be switched off Coolant level Alarm lamp lights when the contact is activated and the engine is switched off NOTE Engine protection can be switched off Charge air temperature Standard value Volvo Penta 100 C 212 F 102 C 216 F NOTE Engine protection can be switched off Oil pressure Standard value Vo
82. sleeve O in the 23 pin connector Check the contact pressure in sleeve 36 in the black cable glove of the engine control unit ECU 224 Code 4 4 Cause Overspeed alarm Short to negative Response Alarm lamp lights constantly Corrective action Check that the wiring and connection to the alarm lamp are not damaged 225 Code 4 4 Cause Overspeed alarm Short to positive Response Alarm lamp does not work If the circuit is interrupted during start up diagnostics are deacti vated Corrective action Check that the wiring and connection to the alarm lamp are not damaged 33 Group 23 EDC III 203 Code 4 5 Cause Low coolant alarm Circuit interruption Response Alarm lamp does not work If the circuit is interrupted during start up diagnostics are deacti vated Corrective action e Check the alarm lamp Check that the wiring to the alarm lamp is not damaged Check sleeve N in the 23 pin connector e Checkthe contact pressure in sleeve 33 in the black cable glove of the engine control unit ECU 204 Code 4 5 Cause Low coolant alarm Short to negative Response Alarm lamp lights constantly Corrective action Check that the wiring and connection to the alarm lamp are not damaged 205 Code 4 5 Cause Low coolant alarm Short to positive Response Alarm lamp does not work If the circuit is interrupted during start up diagnostics are deacti va
83. ssary safety me asures prior to the start of welding or grinding work in the vicinity Always keep a fire ext inguisher easily accessible at the workplace Ensure that rags saturated with oil and fuel used fuel and oil filters are kept in a safe place prior to their disposal Under certain conditions sponta neous combustion can occur in oil ingrained rags Used fuel and oil filters are environmentally hazar dous waste and together with used lubricating oil contaminated fuel residual paint solvents deg reasers and residual detergents should be taken to a suitable plant for destruction Batteries should never be exposed to open fla mes or electric sparks Never smoke near the bat teries When the batteries are being charged they give off hydrogen which when mixed with air forms oxyhydrogen gas This gas is highly flam mable and very explosive A spark which can oc cur if the batteries are connected incorrectly could cause a battery to explode resulting in inju ry and damage Do not disturb the connections when attempting to start risk of sparks and do not lean over any of the batteries Group 23 EDC Ill Safety information A A Never mistake the positive and negative poles for each other when installing the batteries This could cause serious damage to the electrical equipment Compare with the wiring diagram Always wear protective goggles when charging and handling batteries The battery electrolyte contai
84. ssure monitor 8 pin connection Data bus 23 pin connection Stand alone Coolant temperature sensor Starter motor Starter motor relay Tachometer sensor flywheel Water monitor fuel filter Unit injectors one per cylinder Group 23 EDC III Limit values Limit values Limit values electronic control unit ECU TAD1240GE TAD1241 42GE VE Alarm values The maximum permissible values for charge air and coolant temperatures for example can be adjusted with the parameter setting tool and can thus vary within alarm limits If the alarm values are exceeded the system reduces the amount of fuel until the value is once again within the permissible interval This function is a customer parameter that can be completely disengaged Alarm limits TAD1240 42GE VE Coolant temperature Alarm lamp lights Engine is switched off Engine output 50 Standard value Volvo Penta 98 C 208 F 100 C 212 F Parameter setting can be set by the customer 95 101 C 203 214 F 2 C 36 F over the alarm value NOTE Engine protection can be switched off Coolant level Alarm lamp lights when the contact is activated and the engine is switched off Alarm switch is activated NOTE Engine protection can be switched off Charge air temperature Standard value Volvo Penta 83 C 181 F 85 C 185 F NOTE Engine protection can be switched off Oil pressure Standard value Volvo Penta Idle 0 7 bar 10 2 psi For oil pressure 0 3 ba
85. ted Corrective action Check that the wiring and connection to the alarm lamp are not damaged 41 Code 4 6 Cause Start relay on starter motor Short to positive Response Engine will not start Corrective action Check that the wiring to the relay is not damaged Check the function of the relay 34 Diagnostic function 42 Code 4 6 Cause Start relay on starter motor Short to negative Response Engine will be started gt The starter motor engages but no start request is made when the igni tion is switched on Engine running gt The starter motor engages but no start request is made Engine being started gt The starter motor does not di sengage once the engine is started Corrective action Check that the wiring to the relay is not damaged Check the function of the relay 107 Code 4 6 Cause Starter motor relay Circuit interruption Response Engine will not start Corrective action e Check that the cable to the starter motor yellow black is correctly connected Check that the cable to the starter motor yellow black is not damaged Check that the relay on the starter motor is whole Check the contact pressure in sleeve 31 in the red cable glove of the engine control unit ECU 108 Code 4 7 Cause Start input engine control unit ECU Short to negative Response Engine will not start Corrective action Check that the wiring to the ign
86. ter is not damaged e Check the function of the potentiometer Group 23 EDC Ill 181 Code 3 1 Cause 1 Oil pressure sensor Short to positive Response None Corrective action e Check that the wiring to the oil pressure sensor is not damaged Check that the oil pressure sensor is connected correctly 182 Code 3 1 Cause Oil pressure sensor Interrupted or shorted to negative Response None Corrective action Check that the wiring to the oil pressure sensor is not damaged Check that the oil pressure sensor is connected correctly Check the contact pressure in sleeve 14 in the black cable glove of the engine control unit ECU 25 Code 3 2 Cause Charge air temperature sensor Interrupted or shorted to positive Response None Corrective action Check that the connector of the charge air tempe rature sensor is fitted correctly Check that the wiring to the charge air temperature sensor is not damaged Check that the charge air temperature sensor is fitted correctly Check the function of the charge air temperature sensor Check the contact pressure in sleeve 2 in the black cable glove of the engine control unit ECU Diagnostic function 26 Code 3 2 Cause Charge air temperature sensor Short to negative Response None Corrective action e Check that the wiring to the charge air temperatu re sensor is not damaged Check that the charge air t
87. that have been corrected or that have disappeared are erased automatically 2 Error codes for disturbances that have not been corrected must be acknowledged and read out every time the power is turned on If the diagnosis button is pushed after the error has been corrected and saved error codes are erased the code 1 1 No errors will blink out 28 Diagnostic function Group 23 EDC Ill Diagnostic function Error codes EDC Il A WARNING Read the safety instructions for maintenance and service work in the chapter Safety informa tion before starting to work NOTE The readout of the error codes below such as 175 Code 2 1 means that 175 is read using the diagnostic tool 2 1 is the blink code that is shown on the instrument box s diagnostic lamp See Reading out error codes 175 Code 2 1 Cause Water in the fuel or low fuel pressure Response Alarm lamp lights Corrective action Check the fuel dehumidification filter drain the fuel tank e Check if it is possible to increase the pressure using the hand pump e Check the fuel filter Check the fuel pre filter 191 Code 2 2 Cause Low coolant level Response Engine is switched off if this protective feature has not been disabled by the parameter set ting tool Alarm lamp lights Corrective action Check the coolant level Check the function of the coolant level monitor 15 Code 2 4 Cause Tachometer sensor flywheel No si
88. tructions below so as not to damage the control unit of the EDC system Never cut off the main current when the engine is running Never disconnect battery cables when the engine is running When quick charging the batteries the main switch must be turned off or the battery cables must be discon nected During normal maintenance charging the main switch does not need to be turned off Only batteries should be used for jumping Jumping devices may cause a surge and damage the control unit Cut off power to the EDC III system before disconnecting the 2 x 36 pin cable glove from the control unit If damage to the wiring harness is detected the cable glove should be disconnected from the control unit A IMPORTANT The cable glove should be disconnected from the control unit when welding 22 When removing a connector from a sensor be careful not to expose the contact pin to oil or any other fluid This could cause a contact problem or if oil runs down to the pressure sensing membrane the sensor could show an incorrect value Group 23 EDC III Electronic Control unit ECU replacement 1 2 Cut off power to the engine Remove the fuel cooling coil and fuel line clamps from the control unit Bend aside the cooling coil Disconnect the cable glove from the control unit Press in the catch 1 and push the cable glove 2 upwards Remove the control unit Transfer the rubber cushions to the new control unit F
89. uctive sensor It reads the crankshaft position and engine speed using grooves in the flywheel The signal is sent to the control module which calculates the injec tion angle and amount of fuel Charge air pressure temperature sensor 6 Charge air pressure and charge air temperature are measured with a combined sensor located on the inta ke manifold The charge air pressure sensor measures absolute pressure which is the sum of the charge air pressure and atmospheric pressure The sensor sends a signal to the control module in the form of voltage that is pro portional to the absolute pressure The sensor receives a reference voltage of 5 Volts from the control module The charge air temperature sensor consists of a non linear resistor whose resistance depends on the tem perature of the resistor body Resistance decreases as temperature increases Coolant temperature sensor 15 The sensor is located on the left hand rear portion of the cylinder head The sensor reads the temperature of the engine coo lant and sends the information to the control module It consists of a non linear resistor whose resistance depends on the temperature of the resistor body Re sistance decreases as temperature increases Fuel pressure monitor 12 The monitor is located on the left hand side of the engine mounted in the fuel filter bracket Its task is to detect if the fuel pressure falls below 29 psi 2 BAR The monitor is set to shut
90. ule The calculation gives the amount of time the fuel valve is closed as fuel is in jected into the cylinder when the fuel valve is closed The parameters that determine the amount of fuel in jected are Requested RPM e Engine protection functions Temperature e Charge air pressure Cylinder balance When idling the control module can provide the cylin ders with different amounts of fuel This makes the engine idle more evenly At higher RPM all cylinders receive an equal amount of fuel Diagnostic function The EDC III system has an internal diagnostic func tion that makes it possible to detect faults in the engi ne and sensor The role of the diagnostic function is to detect and lo calize disruptions in the EDC III system protect the engine and ensure that the machine remains in wor king order during serious disturbances If a disturbance arises the diagnostic indicator on the indicator panel begins blinking When the diagnosis button is pressed an error code is given as guidance for any fault detection The diagnostic function can be read out via the display using the PC diagnostics pro gram Idle adjustment low idle Idle can be adjusted to a value between 600 and 1200 RPM Design and operation Group 23 EDC III Design and operation Component description The digits after the headings refer to Component dia gram and location Water monitor fuel pre filter 19 The monitor is locat
91. ument illumination 8 Idle contact two position Genset 9 1500 1800 contact two position Genset 10 Starter contact non locking 11 Stop contact non locking 12 Diagnosis contact non locking 13 Alarm low oil pressure 14 Alarm high oil temperature on ube _ 23 45 Alarm high coolant temperature IHRER IE 16 Alarm coolant level n LSB 28 e SB 16710 8 17 Fuel alarm Se oh 1 18 Diagnostic lamp d ii ee i 19 Overspeed indicator Genset on ap as I ar T A 20 Operation indicator Genset 21 Preheating indicator zm 2 Versatile 22 Preheating contact ar SB ELE non locking Versatile oe Zeg ol e 23 8 pin Deutsch connection 12 a ef a A 18 Ai pin SRY i 24 Regulator contact two position Lj 25 Charge indicator Ss any 123 485 8 7 8 2 26 Termination 120 W 2 g 27 8 pin Deutsch connection i T 42345478 sleeve S Gaon 26 28 Control Interface Unit CIU 24 2 D BCE met 4 8 i ella uu a a EE Se SS 8 s tn ER pes Mee 1 10 as a ech BEL mmi 11 E vo ol PRL ___ 12 16 P at ALR D 3 10 Da e DL A SE EA ge Dep e H SE 3 A 33 Lisa c Se 7 ese E PF po ai 3 5 SCT ep HEI d gt a om BL a q se ae 2 Y i 6 An BL Gi DEL e oF F e RZL ZG 18 AAI a WEER why EM DL Pa i i Si BL OR e D RL 33 PSB RE 18 GER 36 H 18 yoa Gi HEL D CH e AEL H 21 WGN A A 24 GI os Op oe DEL Group 23 EDC Ill Electrical

1241 WS4

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