EMS2 Installation ManualD16 - US

Installation I
Industrial Engines 1(1)

EMS 2
TAD1640GE, TAD1641GE, TAD1642GE, TWD1643GE, TAD1641VE
TAD1642VE, TAD1643VE, TAD1650VE,TAD1650GE,TAD1651GE
TWD1652GE, TWD1653GE, TAD1660VE, TAD1661VE, TAD1662VE
TAD1640VE-B, TAD1641VE-B, TAD1642VE-B
Content
Safety Information ...................................................................................... 2
Installation Tools and Documentation ...................................................... 4
Special Tools ............................................................................................ 4
System Information .................................................................................... 5
EMS ........................................................................................................... 5
Control System Installation ..................................................................... 50
Connection ............................................................................................. 50
Calibration and Settings ........................................................................... 71
Parameter Setting .................................................................................. 71
Diagnostic Function ............................................................................... 92
Fault Code Register ............................................................................... 95
Alphabetical index .................................................................................. 109
47701683 10-2012 © AB VOLVO PENTA 1

Safety Information
Presentation Working methods
This installation manual contains information for The work must be performed by a Volvo Penta work-
installing and carrying out function and performance shop or other authorized, well-equipped workshop by
checks on the EMS 2 system (electronic control of the qualified and experienced personnel.
injection system). These instructions refer to such personnel as fitters.
This instruction manual is intended only for professio- This installation manual is intended to be used
nal use. together with the operator's manual for the engine
Read the instructions carefully before starting the concerned. The fitter is responsible for ensuring that
installation. If the installation is performed in an incor- the system functions in accordance with these instal-
rect manner, it may cause personal injury or damage lation instructions.
to property and machinery. Volvo Penta disclaims all responsibility for injury to
Ask your Volvo Penta dealer for help if there is any- persons or damage to property that may occur as a
thing in this manual that you do not understand or are result of not following the installation guidelines, or for
uncertain about. work carried out by unqualified personnel.
!
This symbol is used in the manual and on the product to call attention to the fact that
this is safety information. Always read such information very carefully.
Safety texts in the installation manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT!
Indicates a situation which, if not avoided, could result in property damage.
NOTICE! Used to draw attention to important information that will facilitate work or
operations.
This symbol is used on our products in certain cases and it refers to important
information in the operator's manual. Make sure that warning and information symbols
on the engine are clearly visible and legible. Replace symbols that have been damaged
or painted over.
2 47701683 10-2012 © AB VOLVO PENTA

Safety Information
Set out below is a summary of the risks and safety measures that must be observed or carried out when the EVC
system is installed and calibrated.
! !
Disconnect connectors to the EMS control unit before Never expose battery compartments to open flames
any arc welding is carried out. or electrical sparks. Never smoke in the vicinity of the
Turn the current off at the main switches. batteries.
Undo and remove the control unit connectors. Batteries generate hydrogen gas during charging,
Reconnect the EMS 2 control unit connectors once which can combine with air to form an explosive mix-
welding is completed and the welding equipment has ture. This gas is highly flammable and explosive.
been removed. Incorrect connection of the batteries may cause
sparks that in turn cause an explosion resulting in
! damage.
Take care to keep clear of the engine's moving parts Do not switch battery connections when attempting to
during functional checks and operations. There is a start the engine (risk for sparks) and do not lean over
risk for personal injury when approaching a running the batteries. Refer to the instructions in the engine
engine. Remember that loose clothing and long hair operator's manual.
can fasten in rotating parts and cause serious injury.
!
! Make sure that the positive (+) and negative (-) battery
Never work on an engine that is suspended from lifting cables are correctly connected to the corresponding
gear (a crane or similar). battery terminals. Serious damage may be caused to
! the electrical equipment if the cables are transposed.
The engine must not be run in areas where there are Refer to the wiring diagram in the engine operator's
explosive materials or gases. manual.
! !
Only start the engine in well-ventilated places. If the Always wear eye protection when charging or han-
engine is operated in an enclosed space, make sure dling the batteries. Battery electrolyte contains sulfu-
that there is sufficient ventilation to remove the ric acid which is highly corrosive. If electrolyte comes
exhaust gases and crankcase fumes from the work- into contact with bare skin, wash the exposed area
place. immediately with copious amounts of clean water and
soap. Then seek medical attention. If you get battery
electrolyte in your eyes, flush them immediately (pref-
erably using eye wash equipment) with copious
amounts of clean water. Then seek immediate medi-
cal attention.
47701683 10-2012 © AB VOLVO PENTA 3

Installation Tools and Documentation, Special Tools
Installation Tools and Documentation
Special Tools
p0005125
3838619 VODIA, diagnostic 88890074 Multimeter

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

Other special equipment
The tools below are used for work on the engine wire harness. The tools are not part of the Volvo Penta range,
and must be ordered from AMP or Deutsch dealers. Contact Volvo Penta Quality Action Center if you have trouble
finding a dealer.
AMP connector: 42-pin CIU, 62-pin EMS, 2 and 3 pin Bosch etc.
P0003813 P0003809
HDT-48–00 AMP 539 968 AMP 726 519

Press tool Removal tool, 1.5 mm pin width Removal tool, 0,06 inch pin width
P0003811
P0003810 P0003813
AMP 726 519 AMP 929 039 AMP 238 635

Removal tool, 2.8 mm pin width Removal tool, 2.8 mm pin width Press tool
P0003811 P0003814
AMP 825 514 GHW 50000 017 586

Press tool Removal tool, 2.8 mm pin width
For 4.8 and 6.3 cable shoes. For GHW connector (relay box)
Flat-pin connectors.
4 47701683 10-2012 © AB VOLVO PENTA

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

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

signals for the rpm-potentiometer and the start and
stop knobs are taken over by the J1708/J1587 link.
However, instrument and indicator lamps are com-
pletely turned off. If a fault occurs on both links, GE
engines maintain engine speed, while VE engines go
to idle. The only way to shut off the engine in this case
is to use the auxiliary stop (AUX-STOP) placed on the
engine’s left side.
47701683 10-2012 © AB VOLVO PENTA 5

CIU (Control Interface Unit)

The CIU is a “translator” between the CAN bus and the
customer’s own control panel. This unit has two serial
communication links, one fast and one slow. The fast
one is a CAN link that features a bus speed of 250 Kbit/
s. All data regarding instruments, indicator lamps, con-
tacts and potentiometers are controlled by this bus.
The slower J1708/J1587 link handles diagnostic infor-
mation for, among other things, the flashing code. The
diagnosis tool VODIA also uses the J1708/J1587 link
to communicate with the system.
P0002060
6 47701683 10-2012 © AB VOLVO PENTA

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

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

The amount of fuel that is sprayed into a cylinder is
calculated by the control module. The calculation
determines the time that the fuel valve is closed (when
the fuel valve is closed fuel is sprayed into the cylin-
der).
The parameters controlling injected amount of fuel
are:
• Requested engine speed
• Motor protector
• Temperature
• Boost air pressure
47701683 10-2012 © AB VOLVO PENTA 7

In- and out signals

Information from the sensors provides exact reports
regarding operational circumstances and makes it
possible for the control unit processor to calculate the
correct injection amount, injecton timing and engine
condition, among many other things.
Input signals
The control unit receives input signals regarding
engine operational conditions along with information
from the following components:
- Coolant temperature sensor
- Charge air pressure / charge air temperature sen-
sors
- Crankcase pressure sensor
- Position sensor
- Camshaft
- Engine speed sensor
- Flywheel
- Cylinder cooling pressure sensor
- Coolant level sensor
- Oil pressure sensor
- Oil level and oil temperature sensors
- Fuel pressure sensor
- Water in fuel sensor
- Air filter pressure sensor
- Air temperature sensor
- Exhaust temperature sensor (TWD1643GE)
8 47701683 10-2012 © AB VOLVO PENTA

Output signals
The control unit uses the input signals to control the
following components:
- Unit injectors
- Starter motor
- Alternator
- Main relay
- Pre-heat relay
- Wastegate (TWD1643GE, TAD1650VE)
- Cold start valve (TWD1643GE)
- Valve mechanism, internal EGR (TAD1650VE)
- Electronic fan control
47701683 10-2012 © AB VOLVO PENTA 9

Instruments
DCU (Display Control Unit)
DCU is a digital instrument panel that communicates
with the engine control unit via the CAN-link. DCU has
several functions, such as:
Engine control
- Start, stop, rpm regulation, preheating, etc.
P0002932
Monitoring
- Shows engine speed, charge pressure, charge tem-
perature, coolant temperature, oil pressure, oil tem-
perature, engine hours, battery voltage, instantane-
ous fuel consumption and fuel consumption (trip
fuel).
Diagnostic
- Shows fault codes in text. Lists previous faults.
Parameter setting
- Idle speed, alarm limits for oil temperature/coolant
temperature, regulation mode (speed droop/
isochronous).
DU (Display Unit)
DU is an instrument for showing the engines operating
values. The values are shown graphically on an LCD
display. The display communicates via the CAN link
and consists of a computerized unit for attachment to
the control panel.
It is connected to the CAN link between the engine
control unit and CIU or DCU.
P0002061
10 47701683 10-2012 © AB VOLVO PENTA

Electrical interface
General
This document describes how the Volvo Penta indus-
trial engines equipped with the control systems EMS
and EMS2 may be controlled.
There are a number of interfaces available to control

the engine. The interfaces are:
• Bus interface
• CIU
• DCU
The common thing about the three first interfaces is
that the engine is controlled over two serial communi-
cation buses. The CIU and DCU uses the bus interface
to communicate with the engine.
IMPORTANT!
If non Volvo Penta equipment is connected to the com-
munication busses there is always a risk that the safety
of the system is jeopardized.
47701683 10-2012 © AB VOLVO PENTA 11

Abbrevations
BAM Broadcast Announce Message
CAN Controller Area Network
DEF Diesel Emission Fluid
EATS Engine After Treatment System
EIC Engine Interface Connector
EECU Engine Electronic Control Unit
EMS Engine Management System
EMS 2 EMS used on TAD734GE, D9,
TAD125xVE, D13 and D16 engines
FMI Failure Mode Identifier
OEM Original Equipment Manufacturer
SPN Suspect Parameter Number
VP Volvo Penta
Relevant dokumentation
• 7748665
Electrical interface specification industrial engines
EMS and EMS2
• SAE J1939-73
• SAE J1939-71
12 47701683 10-2012 © AB VOLVO PENTA

Engine control interface

Volvo Penta industrial engines can be controlled in
three different ways. Via bus interface, CIU or DCU.
The bus interface is used by those who makes there
own control system that and wants to control the
engine over SAE J1939 and J1587. Volvo Penta pro-
vided two different systems to control the engines, CIU
that provides a number of digital/analogue outputs to
control the engine. And DCU that has all buttons
included in the unit but still provides some digital/
analogue inputs and outputs.
CIU
This is the interface for those who wants to make there
control panel or non bus based control unit.
DCU
This is the interface for those who wants a complete
unit that is ready to run the engine without make any
button. But the possibility to make some customization
is still here.
The DCU is equipped with a display that shows engine
data and diagnostics translated to text.
Electrical interface
Bus interface
8-pole deutsch connector recepticle.
Pin Description
1 CAN H
2 CAN L
3 Battery –
4 Battery +
5 Ignition and stop request if energized to run
6 Stop request energized to stop
7 J1587A
8 J1587B
47701683 10-2012 © AB VOLVO PENTA 13

CIU
The electrical interface to the CIU is 42-pole AMP con-
nector.
Pin Description Pin Description

1 Idle request 22 J1587A
2 Potentiometer ground 23 Not used
3 Potentiometer signal 24 Preheat indication(1)
4 Not used 25 Coolant level alarm
5 Not used 26 Oil pressure alarm
6 Not used 27 Battery +
7 Over speed indication(2) 28 Ignition (key switch)
Buzzer (3)
8 Easy link bus 29 Governor mode request
9 Coolant temperature alarm 30 Potentiometer supply
10 Battery alarm 31 Not used
11 CAN L 32 Not used
12 CAN H 33 Tachometer
13 Gauge power supply 34 Coolant temperature gauge
14 Battery – 35 Start request
15 Frequency select(4) 36 Diagnostic indication
16 Diagnostic switch 37 J1587B
17 Preheat request(5) 38 Running indication(6)
18 Not used 39 Fuel alarm
19 Engine protection override req. 40 Oil temperature alarm
20 Oil temp gauge 41 Stop request
21 Oil pressure gauge 42 Not used
There is a cable harness available with all wires con-

nected that applies to the above table.
All indicators shall be less than 3W. All switches are
active when shorted to battery+.
1. Not for 124xGE

2. Genset only
3. Power pack only
4. Genset only
5. Not for 124xGE
6. Genset only
14 47701683 10-2012 © AB VOLVO PENTA

DCU
Connector 1, 8-pole deutsch connector.

1 CAN H 5 Ignition and stop request if energized to
run
2 CAN L 6 Stop request energized to stop
3 Battery – 7 J1587A
4 Battery + 8 J1587B
Connector 2, 12-pole deutsch connector:

1 External stop 7 Throttle + (10V)
2 External Start / Ignition 8 Throttle input
3 LSS1 (Buzzer) 9 Throttle –
4 Easylink gauge power 10 LSS2 (Running indication)
5 Easylink Data 11 LSS3 (spare)
6 Easylink Ground 12 LSS4 (spare)
All indicators shall be less than 3W. All switches are

active when shorted to battery +.
47701683 10-2012 © AB VOLVO PENTA 15

Power up sequence
The system powers up when the ignition is switched
on.
Start
A start request is addressed by the start signal. The
engine will then start to crank and it will continue to do
so until one of the following conditions becomes true.
• The start signal goes inactive.
• The engine speed exceeds a stated limit, typical
about 480 rpm.
• The cranking time exceeds a stated limit, typical
about 20 s. 30 s for genset engines.
Bus interface
Associated message:
J1939: Start request in VP Status
J1587: Start request in PPID 98
CIU
Associated hardware/input:
Start request.
DCU
Start request.
16 47701683 10-2012 © AB VOLVO PENTA

Power down sequence

To perform a power down the following sequence shall
be performed:
1 Switch off the ignition
2 Send a stop request to the system.
3 When the power down sequence is finished the
engine will stop communicating.
Auto shutdown will power down the system if the igni-

tion is switched off. Different length of time sequences
are being used. (Running engine will continue to run
until a stop request is sent to the system).
External stop
External stop is placed in the 8-pole connector on pin
6.
Energized to STOP / RUN

Default external stop function is set to Energized to
STOP. To use the stop function as Energized to STOP,
apply EMS supply voltage on Pin 6 to stop the engine.
By option or changing a parameter it can be set to

Energized to RUN. To use the stop function as Ener-
gized to RUN, Pin 6 needs EMS supply voltage for the
engine to start and run. To stop the engine EMS supply
voltage needs to be removed from Pin 6.
Energized to RUN on Pin5

If the function “energized to run” is used the extra stop
is on pin 5 together with the ignition.
The main power MUST NOT be switched off before the

power down sequence is finished.
47701683 10-2012 © AB VOLVO PENTA 17

Stop
A stop request is addressed by the stop signal and will
stop the engine.
Bus interface
Associated message:
J1939: Stop request in VP Status
J1587: Stop request in PPID 98
CIU
Stop request.
DCU
Stop request.
18 47701683 10-2012 © AB VOLVO PENTA

Throttle (Synchronizing/Load
sharing)
Versatile
The driver pedal demand is realized by the throttle
request signal. The signal is interpreted as a 0-100%
request where 0% means idle speed and 100% maxi-
mal engine speed. This demand will only be overridden
if an error occur that may damage the engine or a
request with the CAN-message TSC1.
Genset
This is used for controlling the engine speed in order
to synchronize and to perform load sharing. 50% throt-
tle corresponds to 1500 or 1800 rpm.
Bus interface
Associated message:
J1939: Throttle in VP Status
J1587: PPID 132
CIU
Potentiometer supply, signal and ground.
DCU
Increase decrease engine speed buttons or potenti-
ometer supply, signal and ground.
47701683 10-2012 © AB VOLVO PENTA 19

Torque speed control

It is possible to override the throttle that is sent in VP
Status. This is done with TSC1. When controlling the
engine speed from the gearbox (SA = 0x03) it always
have the highest priority.
Bus interface
Associated message:
J1939: TSC1
J1587: N/A
CIU
Associated message:
J1939: TSC1
J1587: N/A
DCU
Associated message:
J1939: TSC1
J1587: N/A
20 47701683 10-2012 © AB VOLVO PENTA

Governor mode
The engine is normally running in isochronal mode. If
there is a need for a smoother controller this can be
realized by an active droop mode signal. When the
governor mode signal is active then droop functionality
is added to the engine speed controller.
Bus interface
Associated message:
J1939: Governor mode in VP Status
J1587: N/A
CIU
Governor mode request.
DCU
Available in the menu.
47701683 10-2012 © AB VOLVO PENTA 21

Idle switch
Versatile
If the throttle request is malfunctioning (meaning that
there is an electrical fault on the potentiometer or the
cable harness) then the idle switch can be used for limp
home driving.
If there is a fault on the pedal signal then the engine
will go to idle speed. If then the idle switch first goes
active (meaning that the driver has released the pedal)
and then goes inactive (meaning that the driver is
pressing the pedal down) then the engine will slowly
ramping up the engine speed. The engine speed will
be ramped up to maximal 80 % of normal maximal
engine speed. When releasing the pedal the engine
will immediately go down to idle speed.
Genset
If an idle request is sent to the engine it will go to idle
speed if the engine unloaded.
Bus interface
Associated message:
J1939: Idle request in VP Status
J1587: N/A
2.11.2 CIU
Idle request.
CIU
Idle request.
DCU
Available in the menu
22 47701683 10-2012 © AB VOLVO PENTA

Preheat
This function is not valid for 124xGE.
When a preheat request is received the engine will
activate the preheat device if the following conditions
are fulfilled.
• The coolant temperature is low.
• The engine is not running.
The preheat device will be activated for a time depend-
ent on the coolant temperature. The engine will also
decide, using the coolant temperature, if after heating
should be used.
Preheating will be terminated immediately if the driver

starts cranking.
It is possible for the costumer, using Volvo Penta

Parameter setting tool, to choose if preheating should
be activated immediately after turning on the ignition
(prior to same conditions as above).
Bus interface
Associated message:
J1939: Preheat request in VP Status
J1587: N/A
CIU
Preheat request.
DCU
47701683 10-2012 © AB VOLVO PENTA 23

Frequency select
This function is only valid for genset applications.
The frequency switch is used for changing the nominal

engine speed (i.e. switching between 1500 and 1800
rpm). For safety reasons the frequency can only be
changed when the engine is stopped.
EMS2 systems
To make a system reset request stop wait 2 second
after the last stop request. Then change the state of
frequency select to the desired engine speed. Then
send a stop request within 10 seconds after the first
stop. The frequency select signal must change value
during the frequency change. I.e. if the engine runs at
secondary speed and the frequency select signal
requests primary engine speed when the first stop is
issued, the signal has to be switched to secondary fol-
lowed by primary engine speed, before the second
stop request is issued.
It is possible to change the frequency using the Volvo
Penta aftermarket tool.
Bus interface
Associated message:
J1939: Frequency select in VP Status and & diagnostic
request in VP Status.
J1587: N/A
CIU
Frequency select.
DCU
24 47701683 10-2012 © AB VOLVO PENTA

Engine protection override

It is possible to request engine protection override.
When such a request is received the engine will deac-
tivate the engine protection for a predefined time.
Genset engines
The engine protection is disabled as long as the
request is active and for another 10s.
Mobile / Versatile / Powerpack

The engine protection is disabled as long as the
request is active and for another 10s, but is maximized
to 60 seconds.
Bus interface
Associated message:
J1939: Engine protection override request in VP Status
J1587: N/A
CIU
Engine protection override request.
DCU
N/A
47701683 10-2012 © AB VOLVO PENTA 25

Communication J1939
Communication
Description of supported frames, signals and mes-
sages.
J1939
The following frames are supported by the EMS. See
following pages.
Tx = transmit, Rx = receive
Identifier Signal name 164xVE 1640-42GE 1643GE 165xVE 166xVE

18E8FF00 Ack Tx Tx Tx Tx Tx
18EEFF00 Address Claimed Tx Tx Tx Tx Tx
18ECFF00 BAM Tx Tx Tx Tx Tx
18FECA00 DM1 Tx Tx Tx Tx Tx
18FECB00 DM2 Tx Tx Tx Tx Tx
18EBFF00 TP.DT Tx Tx Tx Tx Tx
0CF00400 Electronic Engine Controller 1
Drivers Demand Engine, Torque % Tx Tx Tx Tx Tx
Actual Engine, Torque % Tx Tx Tx Tx Tx
Engine Speed Tx Tx Tx Tx Tx
0CF00300 Electronic Engine Controller 2
Accelerator Pedal Pos. 1 Tx Tx Tx Tx Tx
% Load at Current Speed Tx Tx Tx Tx Tx
18FEDF00 Electronic Engine Controller 3
Nominal friction, torque % Tx Tx
0000FEE3 Engine Configuration
Engine Reference Torque Tx Tx
18FEEF00 Engine Fluid Level/Pressure 1
Fuel Delivery Pressure Tx Tx Tx Tx Tx
Engine Oil Pressure Tx Tx Tx Tx Tx
Coolant Pressure
Coolant Level Tx Tx Tx Tx Tx
18FEE500 Engine Hours
Total Engine Hours Tx Tx Tx Tx Tx
18FEEE00 Engine Temperature 1
Engine Coolant Temperature Tx Tx Tx Tx Tx
Engine Oil Temperature 1 Tx Tx Tx Tx Tx
18FEF200 Liquid Fuel Economy
Fuel Rate Tx Tx Tx Tx Tx
18FEE900 Fuel Consumption, Liquid
Trip Fuel Tx Tx Tx Tx Tx
Total Fuel Used Tx Tx Tx Tx Tx
18FEF600 Inlet/Exhaust Conditions 1
Boost Pressure Tx Tx Tx Tx Tx
Intake Manifold 1 Temperature Tx Tx Tx Tx
Air Inlet Pressure Tx
26 47701683 10-2012 © AB VOLVO PENTA


Air Filter 1 Differential Pressure Tx
Exhaust Gas Temperature Tx
18EA0003 Request PGN Rx Rx Rx Rx Rx
18EA0011 Rx Rx Rx Rx Rx
18EA00EA - Rx Rx
0C000003 Torque/Speed Control 1
0C000011
0C0000E6
Override Control Mode Rx Rx Rx Rx Rx
- - Rx Rx Rx
- - - Rx Rx
Requested Speed Control Conditions Rx Rx Rx Rx Rx
- - Rx Rx Rx
- - - Rx Rx
Override Control Mode Priority Rx Rx Rx Rx Rx
- - Rx Rx Rx
- - - Rx Rx
Requested Speed/Speed Limit Rx Rx Rx Rx Rx
- - Rx Rx Rx
- - - Rx Rx
Requested Torque/Torque Limit Rx Rx Rx Rx Rx
- - Rx Rx Rx
- - - Rx Rx
18FEF700 Vehicle Electrical Power
Battery Potential (Voltage), Switched Tx Tx Tx Tx Tx
0CFF4E00 VP Configuration (1000 ms)
Idle engine speed Tx Tx Tx Tx Tx
Start position: 1
Length: 2 bytes
Resolution: 0.125 rpm/bit
Maximum engine speed Tx Tx Tx Tx
Start position: 3
Length: 2
Resolution: 0.125 rpm/bit
0CFF4700 VP Engine industry (50 ms)
Preheat indication Tx Tx Tx Tx Tx
Start position: 1.1
Length: 2 bits
0 = Inactive
1 = Active
2 = Error indication
3 = Not available
Running indication Tx Tx Tx Tx Tx
Start position: 1.3
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
47701683 10-2012 © AB VOLVO PENTA 27


Buzzer Tx Tx Tx Tx Tx
Start position: 3.1
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
Engine protection override ind. Tx Tx Tx Tx Tx
Start position: 3.7
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
General lamp test Tx Tx Tx Tx Tx
Start position: 4.1
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
Buzzer test/Lamp test Tx Tx Tx Tx Tx
Start position: 4.3
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
0CFF4611 VP Status (20 ms)
Start request Rx Rx Rx Rx Rx
Start position: 1.1
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
Stop request Rx Rx Rx Rx Rx
Start position: 1.3
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
Governor mode request Rx Rx Rx Rx Rx
Start position: 1.5
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
Idle speed select Rx Rx Rx Rx Rx
Start position: 1.7
Length: 2 bits
0 = Normal operation
1 = Idle speed request
3 = Not available
28 47701683 10-2012 © AB VOLVO PENTA


Frequency select NA Rx Rx NA NA
Start position: 2.1
Length: 2 bits
0 = Primary engine speed
1 = Secondary engine speed
3 = Not available
Preheat request Rx Rx Rx Rx Rx
Start position: 2.5
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
Engine protection override Rx Rx Rx Rx Rx
Start position: 2.7
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
Accelerator pedal position Rx Rx Rx Rx Rx
Start position: 3
Length: 2 bytes
Resolution: 0.097752 (100/1023) %/bit
0xFEFF = error indication
0xFFFF = not available
Fuel disable request Rx Rx
Start position: 5.1
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
18FEFF00 Water in Fuel Indicator - WFI
Water in Fuel Indicator Tx Tx Tx Tx Tx
18FE5600 AT1 SCR Reagent Tank 1
Information - AT1T1l
AT1 SCR Tank Level (SPN 1761) Tx
Start position: 1.1
Length: 8 bits
0% = Empty Tank
100% = Full Tank
AT1 DEF Tank Low Level Indicator (SPN Tx
5245)
Start position: 5.6
Length: 3 bits
000: off
001: on - Solid
100: on - Fast blink (1Hz)
47701683 10-2012 © AB VOLVO PENTA 29


AT1 SCR Operator Inducement Severity Tx
Start position: 6.6
Length: 3 bits
000: No Inducement active
001: Inducement Severity 1
18FEE400 Shutdown (EPS)
Engine Protection System has Shutdown Tx
Engine
Start position: 5.1
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
Engine Protection System Approaching Shut- Tx
down
Start position: 5.3
Length: 2 bits
0 = Inactive
1 = Active
3 = Not available
0CFEF500 Ambient Condition
Ambient Air Temp Tx
0CFD6E00 SCR1
Average Catalyst Reagent Consumption Tx
Commanded Catalyst Reagent Consumption Tx
NOTICE! The EMS does not support the address claim

procedure and will always have source address 0x00.
The EMS will however respond to an address claim
request.
30 47701683 10-2012 © AB VOLVO PENTA

Location of Sensors
Location of Sensors
TAD1640GE, TAD1640VE-B, TAD1641GE,
TAD1641VE, TAD1641VE-B, TAD1642GE,
TAD1642VE, TAD1642VE-B, TAD1643VE
1 2
11
4
10
5
12
6
9
8
7
14
13
P0002058
1 Coolant level sensor, in expansion tank 8 Water in fuel sensor

2 Charge air pressure and temperature sensor 9 Oil level and temperature sensor
3 Air filter indicator 10 Fuel pressure sensor
4 Flywheel position and engine speed sensor 11 Crankhouse pressure sensor
5 Fuse 12 Coolant temperature sensor
6 Aux stop 13 Piston cooling pressure sensor (not TAD1650/51GE)
7 Oil pressure sensor 14 Camshaft position sensor
47701683 10-2012 © AB VOLVO PENTA 31

Location of Sensors
TWD1643GE
1
2
3
4
10
5
6
9
7 11
8
15
12
14
13
P0002059
1 Coolant level sensor, in expansion tank 9 Oil level and temperature sensor
2 Charge air pressure and temperature 10 Crankhouse pressure sensor
sensor
3 Oil pressure sensor 11 Coolant temperature sensor
4 Airfilter indicator 12 Exhaust temperature sensor
5 Aux stop 13 Piston cooling pressure sensor
6 Fuse 14 Flywheel position and engine speed sensor
7 “Water in fuel” sensor 15 Camshaft position sensor
8 Fuel pressure sensor 16 Solenoid valve, drainage, water trap (optional), not shown
in illustration
32 47701683 10-2012 © AB VOLVO PENTA

Location of Sensors
TAD1650VE
1 2 3
10
7
8 5
66
12
11
P0005187
1 Crankhouse pressure sensor 7 Oil level and temperature sensor

2 Charge air pressure and temperature sensor 8 Water in fuel sensor
3 Flywheel position and engine speed sensor 9 Fuel pressure sensor
5 Aux stop 11 Piston cooling pressure sensor
6 Oil pressure sensor 12 Camshaft position sensor
47701683 10-2012 © AB VOLVO PENTA 33

Location of Sensors
TAD1650GE, TAD1651GE
1 Coolant level sensor, in expansion tank 8 Water in fuel sensor

2 Charge air temp and pressure sensor 9 Oil level and temp sensor
4 Crank sensor (RPM) 11 Crankhouse pressure sensor
6 Aux stop 13 Camshaft position sensor
7 Oil pressure sensor
34 47701683 10-2012 © AB VOLVO PENTA

Location of Sensors
TAD1660VE, TAD1661VE, TAD1662VE
1 2 3 4
11
5
10
9 8
12
13
14
P0014323
47701683 10-2012 © AB VOLVO PENTA 35

1 Coolant level sensor, in expansion tank 9 Oil level and temp sensor
2 Connection to SCR system 10 Fuel pressure sensor
3 Charge air pressure and temperature 11 Crankhouse pressure sensor
5 Flywheel sensor, speed and position 13 Camshaft position sensor
6 Fuses for SCR system 14 Humidity sensor
7 Aux stop
8 Water in fuel sensor
36 47701683 10-2012 © AB VOLVO PENTA

10 13 15
H L
11 12 14 A B
8 16 18
1 2 1 2 3 4 5 6 7 8 1 2 17 1 2 3 4 5 6
R
W
W
SB
BL
7
Y/W
W/SB
R 2,5
GR/Y
W/SB
SB 2,5
CAN 2
R/BL 1,5
Y
SB
2 1234567 19
R
Y
1
SB
86
Y/SB 1 85
SB 4
P2 R/BL 1,5 2 87
R 1,5 30
3
3 5 9 R 1,5
4
R B
1 (1) (2) 5
SB 4 R/BL
P2 C
1 4 6 SB
47701683 10-2012 © AB VOLVO PENTA

SB
(3) (4) B SB
(2) (1) P2
CAN j1939
1
R 2,5
CAN 2
(1) (2)
GN/R
SB1,0
BL/GN
GN/SB
R 1,0
SB 1,0
BN/OR
GR/W
LBN
GR/R
R/BL 1,5
R/BL 1,5
SB 1,5
SB 1,5
SB 1,5
R/Y
OR
Y/W
GN/W
BL/W
BL/GR
GR/Y
BL/OR
11 31 3 4 17 18 27 28 16 23 14 10 8 52 56 57 60 51 55 58 59 61 29 25
h l h l
33 34
32 BA
7 11 47 22 15 29 31 45 46 37 38 40 48 56 32 16 24 59 60 8 33 34 27 58 57
+ - -
SB
W
BL
OR
R 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
W 1,5
31
SB 1,0
Y/SB
W/SB
29
SB 1,5
BN/OR
OR/SB
GR/SB
GR/SB
GR/OR
VO/SB
GR/GN
R/BL 1,5
4 SB SB 1
3 2
1R R 3 1234
2P P4
CAPILLERING
30 STOPPER x8
25 20
4 MAIN RELAY HOLD
1
3 CYL. 1
P2
2 1 CYL. 2
n n 24
CYL. 3
Wiring Diagram
28 27
TAD1642VE, TAD1642VE-B
R/Y
R 25
R/BL
R/BL
R 2,5
CYL. 4
SB 25
SB 2,5
KL 15 50
12345
CYL. 5
23 B+ B- SB 25 31 M 30 21
G
CYL. 6
R 25
26
P0004301 22
37
1 Sensor, oil level 19 Main relay

2 Sensor, fuel pressure 20 Main circuit breaker 10 A
3 Sensor, crankhouse pressure 21 Starter motor
4 Sensor, coolant temperature 22 Battery (24 V)
5 Sensor, coolant level 23 Alternator
6 Piston cooling pressure sensor 24 Pre-heating
7 Sensor, water in fuel 25 Relay pre-heating
8 Connector (not used) 26 Unit injector (Cyl. 1-6)
9 Extra stop 27 Sensor, flywheel
10 J1939 CAN (bus) 28 Sensor, camshaft
11 Battery negative 29 Sensor, charge air pressure/temperature
12 Battery plus 30 Air filter indicator
13 Voltage after key 31 Sensor, oil pressure
14 Stop button (press button) 32 Connector A
15 J1587 (bus) 33 Connector B
16 Jumper 34 Control unit, EMS 2
17 Aux stop 35 Connector (not in usej)
18 VODIA output
Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Grey
OR = Orange
P = Pink
R = Red
SB = Black
VO = Purple
W = White
Y = Yellow
Cable cross section = 0.75 mm2 unless otherwise stated.
38 47701683 10-2012 © AB VOLVO PENTA

TWD1643GE
47701683 10-2012 © AB VOLVO PENTA 39

1 Sensor, oil level 20 Main fuse breaker 10 A

2 Sensor, fuel pressure 21 Starter motor
3 Sensor, crankhouse pressure 22 Battery (24 V)
4 Sensor, coolant temperature 23 Alternator
5 Sensor, coolant level 24 Pre-heating
6 Sensor, piston cooling pressure 25 Relay pre-heating
7 Sensor, water in fuel 26 Unit injector (Cyl. 1-6)
8 Connector (not in use) 27 Sensor, flywheel
9 Extra stop 28 Sensor, camshaft
10 J1939 CAN (bus) 29 Sensor, charge air pressure/temperature
11 Battery minus 30 Air filter indicator
12 Battery plus 31 Sensor, oil pressure
13 Voltage after key 32 Thermostat by-pass valve
14 Stop button (press button) 33 Wastegate valve
15 J1587 (bus) 34 Sensor, exhaust temperature
16 Jumper 35 Connection A
17 Aux stop 36 Connection B
18 VODIA input (diagnosis conn) 37 Engine control unit, EMS 2
19 Main relay
Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Grey
OR = Orange
P = Pink
R = Red
SB = Black
VO = Purple
W = White
Y = Yellow
Cable cross section = 0.75 mm2 unless otherwise stated.
40 47701683 10-2012 © AB VOLVO PENTA

11
1 2
7
CAN BATT 1708
J1939 BATT- SWITCHED J1587
P0004304
CAN 2
H L BATT+ STOP A B 10
26 1 2 3 4 5 6 7 8 12 3 4 5 6
SB
R
W/SB
W
1 2
Y/W
GR/Y
SB 2,5
R 2,5
R/BL 1,5
GR/SB
W
W/SB
23 5
28 6
86
Y/SB 85
1
1 2 2 1 R/BL 1,5 87
2
SB
Y
30
R 15
1 2 3 4 5 6 7 3
R
SB
Y
4
5
8 21
Y 1,0
R/BL
R/BL 1,5
SB SB
2 SB
2
1 1
22 25 12 15
SB SB
4 1 4 4 R/BL 1,0
SB
R R 2
3 2 2 1 1 2 1
P P P
47701683 10-2012 © AB VOLVO PENTA

27
GN/SB
GN/W
BL/GN
GN/R
R 1,0
SB 1,0
GR/R
BN/OR
LBN
GR/R
SB 1,0
Y
BL/W
BL/GR
Y 1,0
GN
Y/SB
OR 1,0
R/W
R/BL 1,5
R/BL 1,5
BN 1,0
SB 1,5
SB 1,5
SB 1,5
Y/W
GR/Y
3 4 11 16 17 18 28 27 23 14 10 8 52 56 30 38 29 25 37 57 60 7 58 59 61 51 55
h l h h l
CONNECTOR B
CONNECTOR A b a
R 2,5
SB 2,5
31 11 7 47 22 45 46 37 38 36 40 44 48 52 56 28 32 12 16 20 24 59 62 60 61 8 33 34 27 58 57
+
-
GR/OR
SB 1,0
R 1,0
BN/OR
GR/GN
OR/SB
GR/SB
GR/SB
VO/SB
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y 1,0
Y/SB
W/SB
W
BL
R/BL 1,5
SB 1,5
9
R
3
2
SB
1
P 4 4231
4 3 MAIN RELAY HOLD 4231
24 2 1
Cyl 1 17
SB 19
4 1
BN 1,0
R/BN 1,0
OR 1,0
R 3 4 3
TAD1650VE
P2 1 2 1 2
R/BL 1,5
n n R 25
BL/OR 2 1 18
Cyl 2
SB 2,5
R/W
Y/SB
R 2,5
13 14 4 3
20
12 3 4 5 SB 25
2 1 B+ B-
Cyl 3 SB 25
G M 30
4 31
3
4 3 R 25
2 1 2
Cyl 4
4 3
2 1 1
Cyl 5
4 3
2 1
Cyl 6
16
41
1 Battery (24 V) 15 Sensor, piston cooling pressure

2 Main switch 16 Unit injector (cyl. 1-6)
3 Starter motor 17 Pre-heat relay
4 Alternator 18 Circuit breaker
5 Main relay 19 Main automatic circuit breaker 10 A
6 Aux stop 20 Pre-heater
7 Connector, engine interface 21 Sensor, coolant level
8 Sensor, coolant temperature 22 Sensor, oil level
9 Sensor, charge air pressure/temperature 23 Sensor, water in fuel
10 VODIA socket (diagnosis socket) 24 Sensor, oil pressure
11 Connector, not used 25 Sensor, fuel pressure
12 Sensor, crankhouse pressure 26 Internal EGR
13 Sensor, camshaft 27 Control unit, EMS
14 Sensor, flywheel 28 Wastegate valve
Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LB = Light brown
N
GN = Green
GR = Gray
OR = Orange
P = Pink
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow
Wire cross-section = 0.75 mm² unless otherwise stated.
42 47701683 10-2012 © AB VOLVO PENTA

TAD1651GE
P0014126
47701683 10-2012 © AB VOLVO PENTA 43

1 Battery (orange indication) (24 V) 17 Pre-heat relay

2 Starter motor 18 Circuit breaker
3 Alternator 19 Fuse, 10 A
4 Main relay 20 Pre-heater
5 AUX stop 21 Sensor, coolant level
6 Control unit, EMS2 22 Sensor, oil level
7 Connector, engine interface 23 Sensor, water in fuel
8 Sensor, Coolant temperature 24 Sensor, oil pressure
9 Sensor, charge air pressure/temp. 25 Sensor, fuel pressure
10 VODIA output 26 Air filter indicator
11 Connector, no use 27 Electrical fan
12 Sensor, crankhouse pressure 28
13 Sensor, camshaft 29 Valve, cold start
14 Sensor, flywheel 30 Valve, wastegate
15 Sensor, piston cooling pressure 31 Connection box
16 Unit injector (cyl. 1-6) 32 Sensor, exhaust temperature
Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LB = Light brown
N
GN = Green
GR = Grey
OR = Orange
P = Pink
R = Red
SB = Black
VO = Purple
W = White
Y = Yellow
Cabel cross section= 0,75 mm² unless otherwise stated.
44 47701683 10-2012 © AB VOLVO PENTA


0,75 SB
0,75 SB
0,75 SB
0,75 GR/OR
B C A E D F
B C A E D F
29 1 BN
1
CONNECTOR A
CONNECTOR B
28
49
31 11
0,75 SB 1 SB 0,75 GN/SB
P1/4
3
0,75 R 1R 0,75 GN/W
BC AED F
4
0,75 R
0,75 BL/GN
0,75 BN/OR
n
31
47
0,75 R 27 0,75 GN/GR 0,75 BL/OR
22
11
0,75 SB 0,75 GN/R
2 5
P1/4
15 29
16
0,75 OR
0,75 GN
P
P
35 39
0,75 BL
0,75 SB
0,75 R
0,75 OR/SB
26
45 46
n
0,75 GR/SB
1R 0,75 R
1 BL/R
17
0,5 GR/W
25
37 38
n
0,75 OR/SB 1 SB 0,75 SB
18
1Y
Y 0,75 SB
36
0,75 R
1Y
0,75 SB
40
30 3 4
44 48
1/4
P
52 56
0,75 GR/R
1 SB
28
0,75 BN/OR
28 32
27
24 1R
12 16
0,75 BL
5
0,75 VO
20 24
CYL.6
CYL.5
CYL.4
CYL.3
CYL.2
CYL.1
1
1Y
M
1
2 3 4
0,75 GR
6
24
IC
5
NCV
NCV
NCV
NCV
NCV
NCV
2
2
4
0,75 W
7
3 1
3 1
3 1
3 1
3 1
3 1
SV
SV
SV
SV
SV
SV
23
0,75 SB
1Y
1Y
0,75 SB
10
1Y 0,75 Y
1 2 3 4 5 6 7
1Y
8
1Y
1Y
1Y
0,75 SB
59
1Y 1Y
1Y
62
1Y 0,75 P
8
1Y 1Y
22 21
H L
0,75 BN/P
60
11
1Y 1Y
1Y
61
0,75 BL/W
0,75 Y/SB J1939 H
1 2 3 4 5 6
52 56
H L
0,75 BL/GR
8
J1939 L
1,5 BL/R
0,75 GN BAT+MAIN REL.
0,75 W/SB
38
33
MAIN RELAY HOLD
0,75 W
0,75 Y/SB J1708 A
0,75 W/SB
29
0,75 BL/R
0,75 W J1708 B
34
1 OR
10
25
0,75 BL
0,75 R/W
27
37
1,5 BL/R 1,5 BL/R

9
58
57
1,5 BL/R 1,5 BL/R

1,5 SB
60
57
23 1 BN
7
0,75 BL/W
%RH
23 43
0,75 BN 1,5 SB
NTC
1,5 BL/R
58
1,5 SB
59
1,5 SB
61
0,75 Y/W
51
0,75 Y/GR 12
55
J1939 H
1 2 3 4 5 6 7 8
22 2,5 SB
2,5 R
J1939 L
BAT.-
BAT.+
BAT. SWITC.
G
1 BL/R
STOP
0,75 W
J1708 A
0,75 W/SB
J1708 B
0,75 R
25 SB
2,5 SB
13
25 R
0,75 R
BAT.+
1 2 3 4 5 6
0,75 W/SB
J1708 B
4 SB 0,75 SB
BAT.-
CAN3 HIGH
0,75 W
J1708 A
21
SB
15 CAN3 LOW
M
SW
R
87
30
87a
20
25 SB
R
86
85
19 17
1,5 R
0,75 R
4R 2,5 R 2,5 R
18 4 SB
4R 4R 14
16
25 R
1 BN
4 3 2 1
4 3 2 1
1 OR
1 BL/R 1 BL/R
1 SB
47701683 10-2012 © AB VOLVO PENTA 45

1 Sensor, oil level / temperature 17 Fuse, 10 A

2 Sensor, fuel pressure 18 Fuse, 30 A
3 Sensor, crankhouse pressure 19 Starter motor
4 Sensor, coolant temperature 20 Main switch
5 Sensor, oil pressure 21 Battery
6 Throttle 22 Alternator
7 Switch, coolant level 23 Humidity sensor
8 Water in fuel connector 24 Unit injector (cyl. 1-6)
9 Stop button 25 Sensor, crank
10 VGT control valve 26 Sensor, camshaft
11 6-pole EATS connector 27 Air filter indicator
12 8-pole engine connector 28 Electric fan
13 6-pole diagnosis connector 29 Sensor, air inlet pressure / intake mani-
14 2-pole EATS connector fold temperature
15 Main relay 30 Control unit EMS2
16 4-pole pre-heat connector
Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Grey
OR = Orange
P = Pink
R = Red
SB = Black
VO = Purple
W = White
Y = Yellow
Cable cross section = 0,75 mm² unless otherwise stated.
46 47701683 10-2012 © AB VOLVO PENTA

47701683 10-2012 © AB VOLVO PENTA 47

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

2 RPM-potentiometer 17 Fuel alarm
3 Tachometer (code 14) 18 Diagnostic lamp
4 Oil pressure, instrument 19 Overspeed indication (GE)
5 Oil temperature, instrument 20 Operation indicator
6 Coolant temperature, instrument 21 Preheating indication
7 Instrument illumination 22 Preheating contact
8 Idle contact, two position 23 8-pin Deutsch connecting plug, engine interface
9 1500/1800 contact, two position 24 Governor contact
10 Start switch, spring return 25 Battery voltage alarm
11 Stop switch, spring return 26 Termination resistance 120 Ohm
12 Diagnosis contact, spring return 27 8-pin Deutsch connecting socket
13 Alarm, low oil pressure 28 Contact, engine protector disconnect
14 Alarm, high oil temperature 29 Easy Link connector block
15 Alarm, high coolant temperature 30 Control Interface Unit (CIU)
Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Grey
OR = Orange
P = Pink
R = Red
SB = Black
VO = Purple
W = White
Y = Yellow
Cable cross section =0.75 mm2 unless other-wise stated.
48 47701683 10-2012 © AB VOLVO PENTA

12345678 8
11
W/SB
Y/W
BL 2,5
R 2,5
GR/Y
SB 2,5
R/BL 1,5
W
1 Y/W
2 GR/Y
3 SB 2,5
4 R 2,5
5 R/BL 2,5
6 BL 2,5
7 W
W/SB
R/BL 1,5
8
SB 2,5
BL 2,5
W/SB
GR/Y
R 2,5
3
Y/W
W
1 1
1 VO 12345678 9
D 2 4
R/Y
C 2 1 2 3 4 5 6 7 8 10
U SB/Y
3
4 R/BL 5
Y 1
5 3
SB 2
6
7 GN/R
8 GN/Y 6
9 GN/SB
7
10 SB/VO
11 SB/GR
12 SB/W
P0004305
1 Stop contact Cable Colors

2 Start contact BL = Blue
3 1-pin connector LBL = Lightblue
BN = Brown
4 Horn, buzzer alarm LBN = Lightbrown
5 Easy Link connector GN = Green
GR = Grey
6 RPM-potentiometer OR = Orange
7 Indicator engine operation P = Pink
R = Red
8 Deutsch 8-pin connector, engine interface SB = Black
9 Deutsch 8-poligt connector, engine interface VO = Violet
W = White
10 Termination resistance 20 Ω
Cable area = 0.75 mm2 unless
11 DCU (Display Control Unit) otherwise specified.
47701683 10-2012 © AB VOLVO PENTA 49

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

must not be filled with petroleum jelly or similar.
50 47701683 10-2012 © AB VOLVO PENTA

Power supply
NOTICE! The engines are equipped with a 2-pole elec-
trical system. This means that the positive and nega-
tive cables from the battery must be connected to the
starter motor terminals.
Thepositive cable from the battery may be run via a
main switch to terminal 30 on the starter motor.
The negative cable from the battery must be con-
nected directly to terminal 31 on the starter motor.
Refer to the illustration below.
30
31
P0003815
47701683 10-2012 © AB VOLVO PENTA 51

Battery specifikation
Max. battery 2x220 Ah (series connected), 1150 A
CCA EN.
Battery charging
Standard for all engines is that batteries are supplied
with power from the alternator.
Battery cable cross-section area

The total length (L) of the positive och negative cables
determines the cable cross sectional area (A).
Max L (m) 8 10 13
(ft) 26.2 32.8 42.6
Min A (mm2) 70 95 120
(in2) 0.11 0.15 0.19
WARNING!
Due to fire risk, the cable area should never be less
than 70 mm2 (0.1 inch2).
52 47701683 10-2012 © AB VOLVO PENTA

TWD1643GE
NOTICE! All engines are equipped with a 2-pole elec-

trical system. This means that the positive and nega-
tive cables from the battery must be connected to the
starter motor terminals.
The battery positive cable may be run via a main
switch to the positive terminal.
The battery negative cable must be connected
directly to the negative terminal. Refer to the illustration
below.
Battery specification
Max. battery 2x220 Ah (series connected), 800 A CCA
DIN.
Battery charging
Standard for all engines is that batteries are supplied
with power from the alternator
Battery cable cross-sectional area

The total length (L) of the positive and negative cables
determines cable cross sectional area (A).
NOTICE! The negative cable may have a maximum

length equivalent to that of the positive cable.
Max L (m) 8 10 13
(ft) 26.2 32.8 42.6
Min A (mm2) 70 95 120
(in2) 0.11 0.15 0.19
WARNING!
Due to fire risk, the cable area should never be less
than 70 mm2 (0.1 inch2).
47701683 10-2012 © AB VOLVO PENTA 53

CIU
TAD1640GE, TAD1641GE, TAD1642GE,
TAD1650GE, TAD1651GE, TWD1643GE
A E
P0004306
A 8-pin Deutsch connector, from wire harness to engine D For the connection cable, refer to the
Instruments page 67 section.
B Connectors, analog instruments E 8-pin Deutsch connector
C 3-pin Deutsch connector, Easy Link instrument F Extension cables, available in the following lengths: 3,
5, 7, 9, and 11 m
54 47701683 10-2012 © AB VOLVO PENTA

Engine control
Refer to System Information page 37 CIU
NO = normally open
NC = normally closed
Start lock (system voltage OFF / ON)

Engine system voltage start current (control unit) is 10
A. Ensure that other components in the installation are
dimensioned for this current load.
Start switch
Switch type: closing (NO), spring loaded.
Stop switch
The stop switch is energized during operations via a

parameter setting. In this case use a normally closed
(NC) switch.
RPM potentiometer
Nominal revolutions minus 120 rpm: 0.3–1.9 V (preset
value 1.17 V)
Nominal revolutions plus 120 rpm: 1.9–4.7 V (preset
value 4.5 V)
A
A
1.17 V 2.84 V 4.5 V

P0005827
P0005828
47701683 10-2012 © AB VOLVO PENTA 55

1500/1800 rpm switch

Two-position contact.
This function allows a frequency change from 50 to 60
Hz.
Idle switch
Closed contact provides idle rpm.
Droop value switch

The switch must be closed to provide rpm droop value.
Primary control switch

Contact, pre-heating
56 47701683 10-2012 © AB VOLVO PENTA

CIU
TAD1640VE-B, TAD1641VE, TAD1641VE-B,
TAD1642VE, TAD1642VE-B, TAD1643VE,
TAD1650VE
A 8-pin Deutsch connector, from wire harness to engine D For the connection cable, refer to the
Instruments page 67 section.
B Connectors, analog instruments E 8-pin Deutsch connector
C 3-pin Deutsch connector, Easy Link instrument F Extension cables, available in the following lengths:
3, 5, 7, 9, and 11 m
47701683 10-2012 © AB VOLVO PENTA 57

Engine control
Refer to System Information page 37 CIU
NO = normally open
NC = normally closed
A Start lock
The start lock switch is used to connect the system
power, pre-heating and start and stop functions.
B Engine system voltage start current (control unit) is 10

A. Ensure that other components in the installation are
dimensioned for this current load.
P0003965
A Stop contact
B ON contact
C Start lock
D Pre-heating contact
Start lock positions

I
Position 0: engine switched OFF
Position I: system voltage ON
Position II: pre-heating ON (spring return)
Position III: start motor ON (spring return)
Position S: stop function ON (spring return)
A
B
C
D
P0003966 E
A Pre-heating
B Start
C Batt +
D 15 start lock
E Stop
58 47701683 10-2012 © AB VOLVO PENTA

Control switch
Accelerator pedal
Idle: 0.3 1.9 V (preset value 1.17 V)
Full throttle: 1.9 4.7 V (preset value 4.5 V)
If an accelerator pedal with different resistance and

voltage values is used, the control unit must be re-cali-
brated using the parameter tool; refer to Connection of
special tool VODIA page 71.
Idle switch
The accelerator pedal has an integral idle switch that
acts as an emergency device if the accelerator pedal
A potentiometer becomes defective.
When the accelerator pedal is depressed, a contact is

B closed and the engine increases in steps to 80 percent
of maximum rpm. When the accelerator pedal is
released, the contact is opened and the engine slows
to idle immediately.
P0004058
47701683 10-2012 © AB VOLVO PENTA 59

DCU
C
A
P0005826
A 8-pin connector from the engine wire harness.

B 3-pin Deutsch connector, Easy Link instrument
C Connectors, analog instruments (options)
60 47701683 10-2012 © AB VOLVO PENTA


The DCU is connected via the 8-pin databus connector
block.
Display (optional)
Stop switch (optional)

Warning and control lamps (options)

Running indication:
Max. power 3 W
Voltage 24 V
47701683 10-2012 © AB VOLVO PENTA 61

Easy Link Instruments

For parallel connection of up to 20 extra VDO instru-
ments. The instruments will automatically find their
own parameter group from the databus. Maximum
Easy Link cable length is 3 m.
The following instruments are available:
GE engines
• Tachometer/operating hours
• Coolant temperature
• Oil pressure
• Oil temperature
• Battery voltage
VE engines
• Oil pressure
• Oil temperature
• Charge air pressure
• Battery voltage
• Alarm monitor
62 47701683 10-2012 © AB VOLVO PENTA

Rpm-potentiometer
Genset engines
The values from the rpm potentiometer in, in or output

signal from the connection to an external load distri-
bution system can be set in the DCU.
Nominal revolutions minus 120 rpm: 0–10 V (preset
value 1 V)
Nominal revolutions plus 120 rpm: 0–10 V (preset
value 9 V)
It is possible to invert the signal; see diagram.
A A
B
B
C C
1V 5V 9V 1V 5V 9V
P0005824
P0005825
A Nominal revolutions + 120 rpm A Nominal revolutions + 120 rpm

B Nominal revolutions (1500/1800 rpm) B Nominal revolutions (1500/1800 rpm)
C Nominal revolutions - 120 rpm C Nominal revolutions - 120 rpm
47701683 10-2012 © AB VOLVO PENTA 63

TAD1641VE, TAD1642VE, TAD1643VE, TAD1650VE
Versatile engines
It is possible to invert the throttle signal; see the dia-

gram below.
P0005815
P0005816
Max. potentiometer value: 0–10 V (preset value 9V)
Min. potentiometer value: 0–10 V (preset value 1V)
64 47701683 10-2012 © AB VOLVO PENTA

Warning and Indication Lamps

The warning and control lamps below are available.
Specification for all lamps:
Max. power 3 W
Voltage 24 V
Refer to the CIUSystem Information page 37.

• Alarm, low oil pressure
• Alarm, high oil temperature
• Alarm, high coolant temperature
• Alarm, low coolant level
• Alarm, low fuel level
• Alarm, low battery voltage
• Diagnostic lamp
• Pre-heat indicator
47701683 10-2012 © AB VOLVO PENTA 65

The warning and control lamps below are available.

Specification for all lamps:
Max. power 3 W
Voltage 24 V
Refer to the CIUSystem Information page 37.

• Alarm, low oil pressure
• Alarm, high oil temperature
• Alarm, high coolant temperature
• Alarm, low coolant level
• Alarm, low fuel level
• Alarm, low battery voltage
• Diagnostic lamp
• Pre-heat indicator
66 47701683 10-2012 © AB VOLVO PENTA

Instruments
Easy Link Instrument (option)
Refer to the System Information page 37 for the engine
concerned.
For parallel connection of up to 20 extra VDO instru-

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

• Oil pressure
P0005054
• Oil temperature
• Battery voltage
Retaining collar Securing bracket
P0005053
P0005052
Extension cable, 3-pole, 1 m
P0005051
A 3-pin connector
B 3-pin connectors
C CIU wiring harness
47701683 10-2012 © AB VOLVO PENTA 67

Instrument, analog (option)

Refer to the System Information page 37 for the engine
concerned.
Tachometer
Use Volvo Penta standard tachometer, graduations 0–
2600 rpm.
Setting code 14. Refer to installation instructions.
P0003961
Oil pressure gauge

Use Volvo Penta oil pressure gauge, graduations 0–
10 bar (0–145 psi).
P0003961
Oil temperature gauge

Use Volvo Penta oil temperature gauge, graduations
40–150 °C (104–302 °F).
P0003961
68 47701683 10-2012 © AB VOLVO PENTA

Coolant temperature gauge

Use Volvo Penta oil temperature gauge, graduations
40–150 °C (105–300 °F).
Diagnostics switch
Switch type: closing (NO), spring loaded. For reading
fault codes, refer to the Calibration and
Settings page 92 chapter.
Contact, pre-heater
Switch type: closing (NO), spring loaded. This contact
activates the pre-heating.
P0003961
47701683 10-2012 © AB VOLVO PENTA 69

Synchronizing Engine Speed

TWD1643GE
Synchronization/load distribution
The system is adapted for GAC synchronization and
load distribution. Use the EAM122 interface module
when connecting to this system. When this system is
used, voltage levels must be adjusted simultaneously
with VODIA, according to the below.
NOTICE! The EAM122 interface module is not sold by

Volvo Penta. Contact a GAC (Governors of America
Corporation) dealership.
A
B A
C
0.7 V 2.75 V 4.8 V

P0005829
A Nominal revolutions +120 rpm

B Nominal revolutions (1500/1800 rpm)
C Nominal revolutions –120 rpm
P0003964
A Rpm control (GN/NO)

B Rpm control (GN/SB)
C Contact to (R/BL 1.5)
70 47701683 10-2012 © AB VOLVO PENTA

Calibration and Settings, Parameter Setting
Calibration and Settings
Parameter Setting
Connection of special tool VODIA
Connection of special tool VODIA
TAD1640GE, TAD1641GE, TAD1642GE, Function
TAD1641VE, TAD1642VE, TAD1643VE It is possible to read and adjust parameters with the
VODIA tool, part no.3838619, as described in the fol-
lowing pages.
The VODIA tool is connected to the diagnostics socket,
a 6-pin connector; refer to VODIA user instructions for
instructions.
P0005817
TAD1650VE
P0001170
47701683 10-2012 © AB VOLVO PENTA 71

Adjustable parameters
NOTICE! Some parameters require special authoriza-

tion.
Primary regulator mode Indicated engine rpm inverted value

Selects the regulator to be used when the regulator Selects the regulator to be used when the regulator
contact is closed. contact is closed.
Alternative modes: ”Isochronous” or ”Droop value” Alternative engine revolutions: 1500 rpm or 1800
Preset mode: ”Isochronous” rpm.
Preset rpm: dependent on the specification ordered.
PTO regulator gradient is used
The gradient is defined either by a droop value in per- Maximum engine revolutions (CIU)
cent if the Regulator roop value parameter is equal to Potentiometer signal voltage on the CIU unit corre-
zero or Nm/rpm if the Regulator gradient parameter is sponding to nominal revolutions (1500/1800 rpm) plus
equal to zero. (+) 120 rpm.
Min. value: 1.90 V
Regulator droop value Preset value: 4.50 V
Selects the droop value magnitude to be used when Max. value: 4.70 V
droop value is activated (percent).
Min. value: 0 % Pre-heating for ignition
Preset value: 4 % Selects whether pre-heating and post heating is to be
Max. value: 8 % activated directly when the ignition is turned on.
The pre-heating and post heating periods are depend-
Stop function ent on coolant temperature.
The CIU unit stop signal is energized during “opera- If the parameter is in ”Off” mode, pre-heating and post
tions” or “stop”. heating must be activated manually via the ignition
Preset mode: ”Stop” lock or pre-heater button.
Alternative modes: “Off” or “On”
Lamp test Preset mode: “Off”
This parameter determines if a lamp test is to be per-
formed when the system is started.
Preset mode: “On”
Idling speed
Setting idle revolutions.
Min. value: 600 rpm
Preset value: 900 rpm
Max. value: 1200 rpm
72 47701683 10-2012 © AB VOLVO PENTA

Adjustable parameters
NOTICE! Some parameters require special authoriza-

tion.
Inverted regulator mode Idling speed

Select if droop value is to be active. Setting idle revolutions.
Alternative modes: “No droop value” or “Variable Min. value: 550 rpm
droop value” Preset value: 600 rpm
Preset mode: “Fixed droop value” Max. value: 800 rpm
TAD1650VE: 700 rpm
Regulator mode
Select if droop value is active. Idle voltage (CIU)
Alternative modes: “Off” or “No” Throttle control input signal voltage to corresponding
Preset mode: ”No” idle at the CIU unit.
Min. value: 0.30 V
Primary regulator mode Preset value: 1.17 V
Selects the regulator to be used when the regulator Max. value: 1.90 V
contact is closed.
Alternative modes: ”Isochronous” or ”Droop value” Voltage max. rpm (CIU)
Preset mode: ”Isochronous” Throttle control input signal voltage to corresponding
full throttle at the CIU unit.
Regulator gradient Min. value: 1.90 V
Determines the droop value to be used (gradient) Preset value: 4.50 V
Min. value: 10 Nm/revolution Max. value: 4.70 V
Preset value: 25 Nm/revolution
Max. value: 128 Nm/revolution Pre-heating for ignition
Selects if pre-heating is to be activated directly the
Stop function ignition is turned on. If the parameter is in ”Off” mode,
Preset mode: ”Stop” pre-heating and post heating must be activated man-
ually via the ignition lock or pre-heater button.
CIU stop function Alternative modes: “Off” or “On”
The CIU unit stop signal is energized during “Opera- Preset mode: “Off”
tions” or “Stop”.
Preset mode: ”Stop”
Lamp test
This parameter determines if a lamp test is to be per-
formed when the system is started.
Preset mode: “On”
47701683 10-2012 © AB VOLVO PENTA 73

Adjustment of speed regulator

NOTICE! The regulator has a basic factory setting that

is optimized to suit the most common generator set
applications. Use the VODIA tool (including EMS soft-
ware), to read and adjust the P, I and D sections of the
engine speed regulator. The adjustment is made to
give more stable and even running of the engine and
to adapt the engine to the specific generator set appli-
cation.
PID = Proportional, Integrating, Differentiating
A = rpm
B = time
1 = Demanded engine speed
2 = True engine speed
A P-value
1
Amplifier (Gain), amplification of the difference
between the actual value and the set value.
A reduced value (Fig.1) gives a weaker responce to

speed deviations. Reduce the P-value to reduce oscil-
2 lations arising from large differences in speed/load
application.
B
Fig. 1 Fig 1
P0016983
P-value too low
A
1
An increased value (Fig 2) gives a shorter response

time. Increase the P-value for faster compensation of
large differences in speed/load.
2
Fig 2
B P-value too high
Fig. 2
P0016984
74 47701683 10-2012 © AB VOLVO PENTA

I-value
A Stabilizes (stability), reacts to the time of the speed
1 deviation.
A reduced value (Fig.3) increases the time taken by

the system to respond after a load change. Reduce
the I-value to reduce the oscillations that arise with
slowly increasing loading.
2
B Fig 3
Fig. 3 I-value too low
P0016985
A
1
An increased value (Fig 4) gives a shorter response
time. Increase the I-value to provide better load
response for slowly increasing loads.
2
Fig 4
B I-value too high or D-value too low
Fig. 4
P0016986
D-value
Compensates (derivative). Reacts to fast changes of
engine speed/load.
A-reduced value (Fig 4) gives a greater sensivity to

A fast changes of engine speed/load. Reduce the D-
value ro reduce oscillations caused by fast changes.
1
An increased value (Fig 5) gives a reduced sensi-
tivity to fast load changes. increase the D-value to
provide a better ability to compensate for fast
changes.
2
B Fig 5
Fig. 5 D-value too high
P0016987
47701683 10-2012 © AB VOLVO PENTA 75

Alarm limits
Alarm threshold, high oil temperature Overspeed limit

A warning lamp is lit at this temperature. Percent above normal revolutions at which the over-
Min. value: 120 °C (248 °F) speed warning is activated.
Preset value: 125 °C (257 °F) Min. value: 0 %
Max. value: 130 °C (266 °F) Preset value: 20 %
Max. value: 20 %
Alarm threshold, high coolant temperature
A warning lamp is lit at this temperature.
Min. value: 95 °C (203 °F)
Preset value: 98 °C (208 °F)
Max. value: 103 °C (217 °F)
Alarm limits
TAD1642VE, TAD1642VE-B, TAD1643VE
Alarm threshold, high oil temperature Alarm threshold, high coolant temperature
A warning lamp is lit at this temperature. A warning lamp is lit at this temperature.
Min. value: 120 °C (248 °F) Min. value: 95 °C (203 °F)
Preset value: 125 °C (257 °F) Preset value: 98 °C (208 °F)
Max. value: 130 °C (266 °F) Max. value: 103 °C (217 °F)
Alarm limits
TAD1650GE, TAD1650VE, TAD1651GE,
TAD1660VE, TAD1661VE, TAD1662VE,
TWD1643GE
Alarm threshold, high oil temperature Alarm threshold, high coolant temperature
A warning lamp is lit at this temperature. A warning lamp is lit at this temperature.
Min value: 120 °C (248 °F) Min value: 95 °C (203 °F)
Preset value: 125 °C (257 °F) Preset value: 98 °C (208 °F)
Max value: 130 °C (266 °F) Max value: 107 °C (217 °F)
76 47701683 10-2012 © AB VOLVO PENTA

Engine protection
Oil temperature Oil pressure

Determines whether engine protection is to be acti- Determines whether engine protection is to be acti-
vated in respect of high oil temperature. A fault code vated in respect of low oil pressure. A fault code is
is registered and the engine is shut down. registered and the engine is shut down.
Alternative modes: “Yes” or “No” Alternative modes: “Yes” or “No”
Preset mode: “Yes” Preset mode: “Yes”
Coolant temperature Piston cooling pressure

vated in respect of high coolant temperature. A fault vated in respect of low piston cooling pressure. A fault
code is registered and the engine is shut down. code is registered and the engine is shut down.
Coolant level Crankcase pressure

vated in respect of low coolant level. A fault code is vated in respect of high crankcase pressure. A fault
registered and the engine is shut down. code is registered and the engine is shut down.
Charge air temperature Overspeed warning shutdown

vated in respect of high charge air temperature. A fault vated in respect of overspeed. A fault code is regis-
code is registered and the engine is shut down. tered and the engine is shut down.
Charge pressure Exhaust temperature (only TWD1643GE)

vated in respect of high charge air pressure. A fault vated in respect of high exhaust temperature. A fault
code is registered and the engine is shut down. code is registered and the engine is shut down.
47701683 10-2012 © AB VOLVO PENTA 77

Engine protection
Oil temperature Oil pressure

vated in respect of high oil temperature. A fault code vated in respect of low oil pressure. A fault code is
is registered and the engine is shut down. registered and the engine is shut down.
TAD1650VE: a fault code is registered and an orange Alternative modes: “Yes” or “No”
or red warning lamp is lit. Preset mode: “Yes”
Alternative modes: “Yes” or “No”
Preset mode: “Yes” Piston cooling pressure
Determines whether engine protection is to be acti-
Coolant temperature vated in respect of low piston cooling pressure. A fault
Determines whether engine protection is to be acti- code is registered and the engine is shut down.
vated in respect of high coolant temperature. A fault Alternative modes: “Yes” or “No”
code is registered and the engine is shut down. Preset mode: “Yes”
Preset mode: “Yes” Crankcase pressure
Coolant level vated in respect of high crankcase pressure. A fault
Determines whether engine protection is to be acti- code is registered and the engine is shut down.
vated in respect of low coolant level. A fault code is Alternative modes: “Yes” or “No”
registered and the engine is shut down. Preset mode: “Yes”
TAD1650VE: a fault code is registered and an orange
warning lamp is lit. ECU temperature (only TAD1650VE)
Alternative modes: “Yes” or “No” Determines whether engine protection is to be acti-
Preset mode: “Yes” vated in respect of high control unit temperature. A
fault code is registered and an orange or red warning
Charge air temperature lamp is lit.
vated in respect of high charge air temperature. A fault
code is registered and the engine is shut down.
Preset mode: “Yes”
Charge pressure
vated in respect of high charge air pressure. A fault
code is registered and the engine is shut down.
Preset mode: “Yes”
78 47701683 10-2012 © AB VOLVO PENTA

CAN bus settings

Background
With new emission legislations the requirements on
customer panels increases and a document describing
what needs to be implemented in the OEM CAN panels
is needed.
Requirements on OEM panels

There is one message that has to be sent to the VP
EECU and that is the VP status message. See section
VP STATUS MESSAGE: OC FF 46 11. Without this
message the EECU will set a fault code on the CAN
bus and disregard more communication.
Engine interface connector (EIC)

The EIC contains 8 pins with the following functions:
1 CAN High
2 CAN Low
3 Battery minus
4 Battery plus
5 Battery after key
6 Extra stop
7 J1587A
8 J1587B
This is where any CAN panel shall connect to battery

plus and battery minus in order to be powered. Battery
after key and extra stop shall get the positive voltage
from pin 4 (battery plus) when powered.
47701683 10-2012 © AB VOLVO PENTA 79

Battery after key - signal

The battery after key - signal is a “wake up” signal to
the EMS. When this pin get powered the main relay will
be activated which will power the EMS and the EMS
will start to communicate.
This pin should have power for as long as the EMS is

supposed to communicate. The EMS will hold this
relay even without getting power via this signal once
the software is up and running. However, in order to
avoid problems in the aftermarket, it shall always be
power on this pin when the EMS is supposed to com-
municate.
NOTICE! The battery after key signal can be config-

ured via VP aftermarket tool. So that the engine will
stop if power is removed from the pin. (Pin 5 in the 8-
pole Engine Interface Connector; EIC).
It shall also always be possible to power this pin with-

out having to start the engine in order to be able to work
on the engine with after market tools.
80 47701683 10-2012 © AB VOLVO PENTA

Battery plus and minus

The battery plus and minus in the EIC is connected to
the battery via the starter motor. I.e. these pins in the
EIC are outputs that are intended to power other CAN
nodes connected to the engine CAN network. Failure
to do this can cause EECU damages.
Power down
When the EMS should be deactivated the power on
battery after key should be removed and a stop signal
should be sent. This will let the EMS save the data it
needs to save and perform a controlled power down.
The VP status message should be sent until the EMS

stops to communicate in order to avoid unnecessary
error codes.
NOTICE! The stop signal can be either the available

CAN stop or the extra stop in the EIC or with the ignition
key.
In both cases the stop signal should only be active for
a limited period of time.
47701683 10-2012 © AB VOLVO PENTA 81

VP STATUS MESSAGE: OC FF 46 11
The VP status message is a VP proprietary J1939
message that the engine always needs to receive for
as long as it is awake. All necessary engine function-
ality can be controlled via this message.
ID: 0C FF 46 11
Byte: 1 bits 8-7 Idle speed select
bits 6-5 Governor mode request
bit 4-3 Stop request
bit 2-1 Start request
Byte: 2 bits 8-7 Engine protection override
bits 6-5 Preheat request
bit 4-3 Diagnosis request
bit 2-1 Frequency select
Byte: 3 all bits Accelerator pedal position
Byte: 4 all bits Accelerator pedal positon
Byte: 5 bits 2-1 Fuel disable request
Table1: The contents of the VP status message.
Power up
The EECU needs to receive the VP status message
within 500ms of power up. If this message is not sent
the EMS will set an error code on the CAN bus com-
munication.
It is recommended that the OEM CAN panel always

send this message when it is powered and that the
panel also controls when the engine should be ignited.
See battery after key - signal for more information
regarding the ignition function.
82 47701683 10-2012 © AB VOLVO PENTA

Stop functionality
There are several ways of stopping a VP engine and
one or two of the following shall be used:
1 Stop request via VP status on CAN.
2 Extra stop signal in EIC. (Engine Interface Control)
3 TAD1660: Ignition Off
None of these stop signal should be continuously

active when the engine is standing still with power to
the EMS. Sending a continuously active stop signal
with ignition on could damage the EMS. See VP status
message for more information about how to send the
CAN stop request.
Engine Speed
ERR
StopRequest_vPStatus 0
Active
Stop signal active < 0,5s
Inactive
P0013957
Figure 2: An example on stopping an engine with a short active stop signal.
47701683 10-2012 © AB VOLVO PENTA 83

Start functionallety
There are two ways to start the engine and they are:
1 Sending a start request via the VP status message
on CAN.
2 Having the EMS powered and turn the engine.
For more information regarding the start request func-

tion see VP status message.
There are four things that will stop the engine from
cranking:
1 The start request signal is deactivated.
2 There is a stop signal activated.
3 The engine rpm is high (this means that the engine
has started)
4 The cranking time has been to long (The EMS will
protect the starter from overheating by not allowing
to crank to long).
ERR
StartRequest_vPStatus 0
Start request activated
Active
Starter motor
turning engine
Start cranking Engine accelerates
Inactive
P0013958
Figure 3: A succesfull start attempt.
84 47701683 10-2012 © AB VOLVO PENTA

Accelerator Pedal Position

The accelerator pedal position part of the VP status
message is two bytes long and the range is 0 - 100%.
For VE engines 0% means idle speed and 100%

means maximum available speed at the current engine
load. If a mobile VE engine does not receive any speed
request it will got to idle speed.
For GE engines 0% means nominal speed -120 rpm

and 100% means nominal speed +120 rpm. In order to
request the engine to run at nominal speed (1500 or
1800 rpm) the pedal position needs to be set to 50%.
If a GE engine does not receive any speed request it
will stay at the last requested speed.
Message Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8

VP70_VP_Status 00 00 FF 01 00 00 00 00
Table 2: An example of the VP status message
In the table above there is an example of how the VP

status message can be sent. The pedal position part
is byte 3 and 4 and byte 4 is the most significant byte
which means that in this case the pedal position is
0x01FF.
Sins the resolution of this signal is 100/1023% / Bit, the

pedal position in percent is calculated as follows:
Pedal position = 511 x (100/1023) ≈50%
47701683 10-2012 © AB VOLVO PENTA 85

Error code presentation

VP engines uses standard J1939 frames for sending
error codes. VP EMS engines uses conversion method
4 when sending error codes on the CAN bus.
The CAN panels always have to display SPN and FMI

numbers on any active error code. It can be completed
with a generic name for the error code but the SPN and
FMI must also be displayed.
Single active error code

For single active error codes the DM (Active Diagnostic
Trouble Codes) is used. Table 3 shows how a DM1
signal from an EMS engine is sent.
DM1 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8

18FECA00x 04 FF 64 00 12 01 FF FF
Table 3: Example on how an EMS engine sends the

error codes.
Byte Value (Hex) Value (Dec) Description

1 0x04 4 Byte 1 includes lamp colour and 4 corresponds do “yellow” lamp.
2 0xFF 255 Not used.
3 0x64 100 First and least significant byte of SPN.
4 0x00 0 Second byte of SPN.
5 0x12 18 Bits 6-8 are the most significant bits of SPN. Bits 1-5 are the FMI value.
6 0x01 1 Bit 8 is the SPN conversion method. Bits 1-7 are the occurrence coun-
ter.
7 0xFF 255 Not used
8 0xFF 255 Not used
Table 4: How to interpret the VP DM1 message.
86 47701683 10-2012 © AB VOLVO PENTA

Multiple active error codes

If there are multiple simultaneously active error codes
the broadcast announce (TP.CM_BAM) and the data
transfer messages (TP.DT) are used in order to send
all error codes.
The CAN panel shall be able to display up to 10 simul-

taneously active error codes. All of them do not need
to be displayed at the same time but it shall be possible
to scroll through them.
NOTICE! When the CAN diagnostics uses the trans-

port protocol, the standard polling is not supported,
meaning that no “request to send” is transmitted and
no “clear to send” is being received. No “end of mes-
sage ack” is received. The EMS will send a BAM and
directly there after follow by DM1 / DM2.
Engine protection functionality

VP engines are designed to protect themselves from
being damaged by e.g. overheating or low oil pressure
and will take action in order to avoid engine damage.
No action should be taken by the CAN panel to stop
the engine in case an engine protection error is sent.
NOTICE! The engine protects itself from being dam-

aged but it does not consider the surrounding it is
installed in.
47701683 10-2012 © AB VOLVO PENTA 87

More available control functions

There are other possibilities than the VP status/pedal
position message in order to control the engine speed.
Torque speed control - TSC1 (0C 00 00 03/11/E6)

The TSC1 message has priority over the pedal position
that is sent with the VP status message. With the TSC1
message with source address 0x03, 0x11, 0xE6, the
engine speed and torque can be continuously control-
led.
With the TSC1 message with the source address 0x11

it is possible to limit the available torque or speed from
the engine.
Torque Limit
2000
1800
1600
1400
1200
Nm
1000
800
600
400
200
0
750 950 1150 1350 1550 1750 1950
P0013959 rpm
Figure 4: The yellow graph shows the available engine torque when the TSC1 signal sets to 80% in the torque limiting factor.
The picture shows an example on how an engine would react when limiting the torque via the TSC1 message.
Start battery test

Whit the fuel disable request in the VP status message,
it is possible to perform a start battery test.
88 47701683 10-2012 © AB VOLVO PENTA

Special requirements with EATS

The engines equipped with exhaust after treatment
systems have some more requirements regarding
which messages that includes error code information.
DEF level
The DEF level is broadcasted on the J1939 bus via
SPN 1761. SPN 1761 will show a value between 0 -
100%
DEF level diagnostics

The DEF level diagnostics are sent via two different
SPN numbers. These SPN numbers are SPN 5245
and 5246 and they are included in the message AT1TI
(PGN 65110). See table 5 for location of these signals
in AT1TI.
SPN Start byte Start bit Length (bits)

5245 5 6 3
5246 6 6 3
Table 5: SPN 5245 and 5246 in PGN 65110 (AT1Ti).
If the DEF level is low SPN 5245 will be sent with a

value that shows how severe the low level is as descri-
bed in table 6.
SPN 5245 Value Severity Level

1 DEF/AdBlue level low. Solid signal.
4 DEF/AdBlue level empty. Flashing with 1Hz.
There are different inducement levels to motivate the

operator to not use the engine when the EATS does
not work properly. The inducement level active is com-
municated via SPN 5246 as described in table 7.
SPN 5246 Value Inducement Level

3 Engine derate
4 Pre severe inducement
5 Severe inducement
6 Temporary override of inducement
DEF symbol
If a symbol is used in the display for any SCR related
SPN, the symbol shown in figure 5 has to be used.
P0013960
47701683 10-2012 © AB VOLVO PENTA 89

Figure 5: The symbol used for DEF functions.
Stop functionality
The stop function in EMS2 works in two different ways
if stop function is set to “energized to run”, described
as follows, (picture).
ETR stands for Energized To Run, and ETS stands for

Energized To Stop
EMS 2 EMS 2.2

(Tier 4)
Engine: 164X/165X Engine 1660/164X VE-B
1 1
2 2
3 3
Battery 4 Battery 4
switch 5 switch 5
Stop 6 ETR / ETS Stop 6 ETR / ETS
7 7
8 8
Fig. 5
P0016988
90 47701683 10-2012 © AB VOLVO PENTA

EMS-2 extra stop

On EMS2 engines the extra stop is level triggered as
shown in figure 7. The default setting is “Energized to
stop” which means that when there is power on this pin
the engine will stop and it will not be able to start until
the stop signal is deactivated.
If the parameter “Stop function EMS, energized to” is

set to run, there needs to be battery power on this pin
in order for the engine to be able to run.
Running
Engine
Running Stopped
Battery +
Energized to
stop Open Circut
No stop STOP!
Battery +
Energized to
run Open Circuit
P0013962
Figure 7: The extra stop functionallety on EMS2 engines.
Never have a stop signal being continuously sent to a

powered control unit. If there is a continuous active
stop signal over time, it could damage the engine con-
trol unit. Figure 1 shows that the stop signal should be
sent as a pulse signal.
The voltage to the stop signal should come from pin 4

in the engine interface connector.
47701683 10-2012 © AB VOLVO PENTA 91

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

system, this is reported using fault codes via the instru-
ments.
Both active (unrectified) and passive (rectified) faults
are stored in the control unit.
Refer to the “Operation” heading for reading fault
codes/fault messages.
All fault codes and fault messages are found in the fault
code list, with information about the reason, reaction
and measures to be taken. Refer to Fault Code Reg-
ister.
NOTICE! All instruments are optional.
Effect on engine
Engines are affected differently, depending on the
severity of the fault discovered by the diagnostic func-
tion.
A fault message in the form of a fault code is always
generated when a malfunction is discovered by the
diagnostic function.
Engines are affected differently, depending on the
severity of the fault:
• The engine is not affected
• Engine goes to idle
• Engine torque is restricted to a certain amount
• Engine is stopped
92 47701683 10-2012 © AB VOLVO PENTA

Active and Inactive Faults

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

• the diagnostic lamp starts to flash.
• ”Easy Link” instrument
- the relevant lamp on the alarm panel lights up
- after the diagnostic button has been pressed,
the fault code is shown as text on the tachometer
display.
DU (Display Unit)
• Either WARNING! or ALARM STOP (a buzzer
sounds) will be shown on the display, depending
on the severity of the fault.
• Fault codes can also be read off using the

VODIA tool. For instructions, see “VODIA User’s
Guide”.
Operation
When a malfunction has occurred and the diagnostic Reading fault codes via the DU (Display Unit)
system has generated one or more fault codes, these Depending on the severity of the fault the text, either
are read out differently depending on the equipment WARNING! or ALARM STOP (a buzzer sounds) will
used. Please refer to “Fault code messages”. be shown on the display
If the system indicates that a fault code has been
1 Press any button to come to the fault list. The
set:
fault list shows operation hours and fault mes-
1 Cut engine speed to idle, or shut the engine off. sage.
2 For DCU/DU 2 Look up the fault code in Fault Code Register
Read the fault code from the display, please and take the recommended measures.
refer to Reading fault codes via the DCU or
3 Press on ACK to acknowledge the fault code.
Reading fault codes via the DU.
The display background will change color (the
For CIU
buzzer stops sounding).
press the diagnostic button and read the fault
code, by observing the flashing of the diagnostic 4 Press on EXIT to leave the fault list.
lamp. Refer to Reading fault codes via the
diagnostic lamp, CIU.
3 Look up the fault code in the Fault Code Regis-
ter chapter and take the recommended meas-
ures.
47701683 10-2012 © AB VOLVO PENTA 93

Reading fault causes via the DCU (Display Control Reading fault codes via an “Easylink” instrument
Unit) When the system has discovered a malfunction, this
When a fault code is set, the following text is shown is reported by the diagnostic lamp which starts to
on the display: flash.
!! ENGINE WARNING !!
1 Press the diagnostic button. The fault code is
alternated withPress SEL for information.
shown as text on the tachometer display.
Read the fault code as follows:
2 Look up the fault code in the Fault Code Regis-
1 Press SEL-button to come to the fault list.
The fault list shows:
ures.
-Operation hours
-Fault message 3 When the fault has been rectified, the fault code
-Active/inactive disappears from the display and the diagnostic
lamp goes out.
2 Look up the fault code in theFault Code Regis-
ures.
3 Press ESC-button to leave the fault list.
NOTICE! To enter the fault list when no fault code has

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

fault codes have been read.
If the diagnostics button is depressed after the fault
has been corrected and the fault code deleted, the
code 1.1, No fault, will be shown.
94 47701683 10-2012 © AB VOLVO PENTA

Calibration and Settings, Fault Code Register
Fault Code Register

CAUTION!
Read through the safety advice before starting any work.
The fault codes below comprise:
- a fault text message displayed when a DCU or DU is installed.

- a flash code, e.g. 5.4, read off from the diagnostics lamp; refer to Calibration and Settings page 92
- a fault code, e.g. PID 45, read off from the VODIA tool.
For references to sleeves in electrical connectors, refer to System Information page 37.
No fault (Code 1.1)

Cause Reaction Remedy
There are no active faults.
Exhaust Temperature (Code 1.9, PID 173/SPN 1184)

• Exhaust temperature to high • Warning lamp lights up • Insufficient air supply
• Engine is shutdown • Low coolant level
• Air in the coolant system
• Faulty circulation pump
• Blocked charge air cooler
• High temperature, charge air-
cooler
• High back pressure in the
exhaust system
• Check wastegate function
Water in Fuel (Code 2.1, PID/SPN 97)

• Water in fuel • None • Empty the primary fuel filter
Coolant Level (Code 2.2, PID/SPN 111)

• Low coolant level • Engine control module • Check the coolant level
reduces engine power
• Check coolant level monitor
(unless the protection has
function
been shut off with the VODIA
diagnostic tool)
Coolant Level Sensor (Code 2.3, PID/SPN 111)

• Short circuit to positive (+) • None • Check that the coolant level
sensor cable is not damaged
• Fault in sensor
• Check coolant level sensor
function
47701683 10-2012 © AB VOLVO PENTA 95

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

• No signal • Engine is very difficult to start • Check that the sensor con-
and runs roughly when it nector is correctly installed
• Abnormal frequency
starts
• Check that the engine speed
• “Intermittent” signal from the
sensor
• Fault in sensor
sensor is correctly installed in
the flywheel housing
• Check engine speed sensor
function
Camshaft Drive Speed Sensor (Code 2.5, SID21/SPN 636)

• No signal • Engine takes longer to start • Check that the engine speed
than normal. Engine runs nor- sensor connector is correctly
• Abnormal frequency
mally when running installed
• Fault in sensor
sensor is correctly installed in
the upper timing gear cover.
• Check engine speed sensor
function.
Engine Speed (Code 2.6, PID/SPN 190)

• Engine speed too high • None • After the engine has stopped,
look for the reason for the high
speed
Speed Potentiometer Connected to CIU (Code 2.8, PPID 132/SPN 91, 608)
• Shorted to plus (+) or minus • Engine goes to idle • Check that the potentiometer
(-) has been connected correctly
• Speed feezes
• Fault in sensor • Check that the cable harness
to the potentiometer has not
been damaged
• Check the potentiometer
function
Indicator for Water in Fuel (Code 2.9, PID/SPN 97)

• Short circuit • None • Check the indicator cables for
breaks and short circuits
• Open circuit
• Check indicator function.
• Fault in indicator
Change indicator as neces-
sary
96 47701683 10-2012 © AB VOLVO PENTA

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

• Short circuit to positive (+) or • None • Check that the oil pressure
earth (ground) (–) sensor cable is not damaged
• Open circuit • Check that the oil pressure
sensor is correctly connected
Boost Temperature Sensor (Code 3.2, PID/SPN 105)

• Short circuit to positive (+) or • None • Check that the boost temper-
earth (ground) (–) ature sensor connector is cor-
rectly installed
• Open circuit
• Check that the boost temper-
ature sensor cable is not dam-
aged
• Check that the boost temper-
ature sensor is correctly
installed
• Check boost temperature
sensor function
Coolant Temperature Sensor (Code 3.3, PID/SPN 110)

• Short circuit to positive (+) or • Preheating is also activated • Check that the coolant tem-
earth (ground) (–) when the engine is hot perature sensor connector is
correctly installed
• Open circuit
• Check that the coolant tem-
perature sensor cable is not
damaged
• Check that the coolant tem-
perature sensor is correctly
installed
• Check coolant temperature
sensor function
Boost Pressure Sensor (Code 3.4, PID/SPN 102/106)

• Short circuit to positive (+) or • Engine smokes more than • Check that the boost pressure
earth (ground) (–) normally during acceleration/ sensor connector is correctly
load increase installed
• Open circuit
• Check that the boost pressure
• Check that the boost pressure
sensor is correctly installed
• Check boost pressure sensor
function
47701683 10-2012 © AB VOLVO PENTA 97

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

Cause Reaction Action
• High charge pressure • Engine power is reduced or • Check that the charge air
engine stops. pressure sensor connector is
correctly installed
• Check that the charge air
pressure sensor cable is not
damaged
• Check that the charge air
pressure sensor is correctly
installed
• Check charge air temperature
sensor function
Fuel Pressure Sensor (Code 3.6, PID/SPN 94)

• Short circuit to positive (+) or • None • Check that the fuel pressure
earth (ground) (–). sensor connector is correctly
installed.
• Open circuit.
• Check that the fuel pressure
sensor cable is not damaged.
• Check that the fuel pressure
sensor is correctly installed.
• Check fuel pressure sensor
function.
Oil Temperature Sensor (Code 3.7, PID/SPN 175)

• Shorted to plus (+) or minus • None • Check that the cable harness
(-) to the oil temperature sensor
has not been damaged
• Break
• Check that the oil tempera-
ture sensor has been con-
nected correctly
Fuel Pressure (Code 3.8, PID/SPN 94)

• Low supply pressure • None • Check if it is possible to build
up pressure with the hand
pump
• Check the fuel filter
• Check the fuel pre-filter
Battery Voltage, EMS (Code 3.9, PID/SPN 158)

• Faulty alternator • None • Check the supply voltage
from the control unit
• Faulty battery, battery cables
98 47701683 10-2012 © AB VOLVO PENTA

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

• Shorted to plus (+) or minus • The engine cannot be started • Check that connections to the
(-) ignition key/start panel have
• The engine starts immedi-
not been damaged
• Activated for too long ately when ignition is turned
on • Check that the cable harness
to the ignition key/sart panel
Stop Input EMS (Code 4.8, PPID 6/SPN 970)

• Short circuit to negative (-) • Engine can only be stopped • Check that the starter switch
with the auxiliarystop connections are not damaged
• Open circuit
TWD1643GE
Exhaust Temperature (Code 4.9, PID 173/SPN 1184)

• Short circuit to positive (+) or • Warning lamp lights up • Check that the exhaust tem-
negative (-) perature sensor connector is
• Engine control unit limits
properly mounted
• Open circuit engine power
• Check that the wiring to the
• Exhaust temperature to high
exhaust temperature sensor
is not damaged
• Check that the exhaust tem-
perature sensor is correctly
mounted
• Check the exhaust tempera-
ture sensor function
Starter Input CIU (Code 5.2, PPID 4/SPN 520194)

• Shorted to minus (-) • The engine cannot be started • Check that connections to the
ignition key/start panel have
• Activated for too long • The engine starts immedi-
not been damaged
ately when ignition is turned
on • Check that the cable harness
to the ignition key/start panel
Stop Input CIU (Code 5.3, PPID 6/SPN 52095)

• Short circuit to negative (-) • Engine can only be stopped • Check that the starter switch
with the auxiliary stop (AUX connections are not damaged
• Open circuit
STOP) on engine
• Check that the ignition switch
• Activated for too long time
• Engine stops. A fault code is cable is not damaged
displayed for 40 seconds and
the engine can not be started
during this time. When a fault
code is active, the engine can
be started but not stopped
47701683 10-2012 © AB VOLVO PENTA 99

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

• Short circuit to positive (+) or • Preheating can not be acti- • Check that the relay input
earth (ground) (–). vated. cable is not damaged.
• Open circuit. • Preheating is constantly con- • Check relay function.
nected.
Air Filter Pressure (Code 5.5, PID/SPN 107)

• Too large pressure drop • Less good response from • Check the air filter
across filter engine
Air Filter Sensor (Code 5.6, PID/SPN 107)

• Shorted to plus (+) or minus • None • Check that the air filter sensor
(-) contact is correctly installed
• Break • Check that the cable harness
to air filter sensor has not
been damaged
• Check the air filter sensor
functionality
Oil Level (Code 5.7, PID/SPN 98)

• Oil level to low • None • Check the oil level
Oil Temperature (Code 5.8, PID/SPN 175)

• Oil temperature is too high • The engine control module • Check the oil level
limits engine output(unless
• Check the oil temperature
protection has been turned off
with thediagnosis tool • Check the oil temperature
VODIA) sensor function
Oil Level Sensor (Code 5.9, PID/SPN 98)

• Shorted to plus (+) or minus • None • Check that the cable harness
(-) to the oil level sensor has not
been damaged
• Break
• Check the oil level sensor
function
100 47701683 10-2012 © AB VOLVO PENTA

Coolant Temperature (Code 6.1, PID/SPN 110)

• Coolant temperature is too • Engine control module • Check the coolant level
high reduces engine power
• Check the charge air cooler
(cleanliness)
diagnostic tool) • Check if there is air in the
cooling system
• Check the pressure cap on
the expansion tank
• Check coolant temperature
sensor function
• Check thermostat function
Boost Temperature (Code 6.2, PID/SPN 105)

• Boost temperature is too high • Engine control module • Check the coolant level
• Check the charge air cooler
(cleanliness)
diagnostic tool) • Check boost temperature
sensor function
• Check the function of the ther-
mostat
Data Link (CAN), CIU (Code 6.4, SID 231/SPN 639)

• Faulty data link (CAN), , CIU • Instruments and warning • Check that the 8-pin connec-
lamps stop working tor is not damaged
• Check that the cables
between the CIU and the
engine management unit are
not damaged
Data Link (CAN), EMS 2 (Code 6.5, SID 231/SPN 639/2017/PSID 201)
• Internal fault in control mod- • Engine not operating: engine • Check that the 8-pin connec-
ule can not be started. Engine tor is not damaged
operating: engine idles and
can only be stopped with the
between the CIU and the
auxiliary stop (AUX-stop)
engine management unit are
not damaged
• Check that sleeves 11 and 12
in the connector on the CIU
are not damaged
47701683 10-2012 © AB VOLVO PENTA 101

Oil Pressure (Code 6.6, PID/SPN 100)

• Oil pressure is too low • Engine control module • Check oil level
• Check that the air filter is not
blocked
diagnostic tool) • Check system pressure
valves and safety valves in
the oil system
• Check oil pressure sensor
function
Piston Cooling Pressure (Code 6.7, PPID 8/SPN 520192)

• Piston cooling pressure is too • Engine stopped • Check that the oil pressure in
low the engine exceeds175 kPa
(25.4 psi)
Piston Cooling Pressure Sensor (Code 6.8, PPID 8/SPN 520192)

• Shorted to plus (+) or minus • None • Check that the piston cooling
(-) pressure sensor contact is
correctly installed
• Break
• Check that the cable harness
to the piston cooling pressure
sensor has not been dam-
aged
• Check the piston cooling
pressure sensor functionality
Battery Voltage, CIU (Code 6.9, PID/SPN 158)

• Short circuit to negative (-) • Problems in engine starting • Check the supply voltage
from the control unit
• Faulty alternator
• Check the batteries
• Faulty battery, battery cables
• Check the alternator
• Check the 8-pin contact
Injector, Cylinder #1 (Code 7.1, SID 1/SPN 651)

• Electrical fault • Engine runs on 5 cylinders • Check that the injector cables
are not damaged
• Faulty compression or injec- • Abnormal sound
tor • Check that the injector con-
• Reduced performance
nections are not damaged
• Check fuel supply pressure
• Check the valve clearance
• Do a compression test and
check cylinder #1
102 47701683 10-2012 © AB VOLVO PENTA


are not damaged
check cylinder #2

are not damaged
check cylinder #3

are not damaged
check cylinder #4

are not damaged
check cylinder #5
47701683 10-2012 © AB VOLVO PENTA 103


are not damaged
check cylinder #6
Crankcase Ventilation Pressure (Code 7.7, PID/SPN 153)

• Crankcase ventilation pres- • The engine is shut down (if • Check whether the crankcase
sure too high the protection has notbeen ventilation is blocked
shut off by the parameter tool)
• Check whether cylinder lin-
ers, pistons or piston rings are
worn or damaged
Crankcase Ventilation Pressure Sensor (Code 7.8, PID/SPN 153)

• Shorted to plus (+) or minus • None • Check that the crankcase
(-) ventilation pressure sensor
contact is correctly installed
• Break
to the crankcase ventilation
pressure sensor has not been
damaged
• Check that the crankcase
ventilation pressure sensor
correctly installed
• Check crankcase ventilation
pressure sensor function
Air Temperature Sensor, Inlet (Code 7.9, PID/SPN 172)

• Shorted to plus (+) or minus • None • Check that the air tempera-
(-) ture sensor contact is cor-
rectly installed
• Break
to the air temperature sensor
• Check that the air tempera-
ture sensor is correctly instal-
led
• Check the air temperature
sensor functionality
104 47701683 10-2012 © AB VOLVO PENTA

TWD1643GE
ECU Temperature (Code 8.4, PPID 55/SPN 1136)

• Control unit too hot, incorrect • None • Check the control unit instal-
assembly lation. Recommended ambi-
ent temperature is 50°C
• Electrical fault, damaged sen-
(122°F)
sor
TAD1650VE
Internal EGR (Code 8.5, PPID 19/SPN 2791)

• Fault in cable harness (boost • Engine control module • Check cable harness (boost
pressure sensor) reduces engine power pressure sensor)
• Mechanical fault on the IEGR • Check the IEGR
• Contact a Volvo Penta
authorized workshop
TAD1650VE, TWD1643GE
Preheating Sensor (Code 8.6, SID 70/SPN 729)

• Fault in cable harness • Preheating can not be acti- • Check the cable harness
vated
• Fault in preheating relay • Check the preheating relay
Faulty data link (J1587) (Code 9.2, SID 250/SPN 608)

• Faulty data link • None • Check that the 8-pin connec-
tor is not damaged
between the CIU/DCU and
the engine management unit
are not damaged
TWD1643GE
Power Supply to Sensor (Code 9.3, SID 211, 232/SPN 1080, 1079)
• Shortcut • Faulty values in oil pressure • Check that the cable harness
and boost pressure sensors to oil pressure and boost
• Fault in sensor
• Fault code for oil pressure-
damaged
and boost pressure sensor
• Check oil pressure and boost
• Low engine output
pressure sensors
• The instrument shows zero oil
pressure and boostpressure
47701683 10-2012 © AB VOLVO PENTA 105

TWD1643GE
Power Supply to Sensor (Code 9.3, SID 211/232, SPN 1079/1080)

• Fault in sensor
damaged
pressure sensors
pressure and boost pressure
Power Supply Sensor (Code 9.3, SID 232/SPN 620)

• Fault in sensor
damaged
pressure sensors
pressure and boost pressure
Data Set Memory EEPROM, CIU (Code 9.8, SID 253/SPN 630)
• Internal fault in control mod- • Engine does not start • Re-program the control mod-
ule ule.
• Programming faulty
Fault in Control Unit, CIU (Code 9.8, SID 254/SPN 629)

• Faulty EEPROM, CIU • CIU returns to factory setting • Re- program the unit
• Faulty flash memory, CIU • Engine goes to idle
• Fault in control module, CIU • Engine can not be started
Memory Fault EMS (Code 9.9, SID 240/SPN 628)

• Memory fault in engine man- • Engine might not start • Re-program the unit
agement system
Data Set Memory EEPROM, EMS (Code 9.9, SID 253/SPN 630)
• Internal fault in control mod- • Engine does not start • Re-program the control mod-
ule ule. If the fault remains,
change the control module
• Internal fault in control mod-
ule
Control Module EMS (Code 9.9, SID 254/SPN 629)

• Internal fault in control mod- • Engine misfires • Change engine control unit
ule
• Engine does not start
106 47701683 10-2012 © AB VOLVO PENTA

Wastegate (SID 32/SPN 1188)

• Short circuit to positive (+) or • Warning lamp lights up • Check that the wastegate
negative (-) connector is properly
• Engine control unit limits
mounted
• Open circuit engine power
• Wastegate damaged
wastegate is not damaged
mechanically
• Check that the wastegate is
correctly mounted
• Check the wastegate
Fan, rpm sensor (PID 26/SPN 975)

• Open circuit • Warning lamp lights up • Check that the fan actuator is
properly mounted
fan actuator is not damaged
• Check that the fan actuator is
correctly mounted
• Check the fan actuator
Fan actuator (SID 33/SPN 975)

• Short circuit to positive (+) or • Warning lamp lights up • Check that the fan actuator is
negative (-) properly mounted
• Open circuit • Check that the wiring to the
fan actuator is not damaged
• Fan actuator damaged
mechanically • Check that the fan actuator is
correctly mounted
• Check the fan actuator
EATS
Fault codes for the EATS system is in the installation
manual for this system.
47701683 10-2012 © AB VOLVO PENTA 107

Alphabetical index
A
Adjustable parameters....................................... 72, 73
Adjustment of speed regulator................................. 74
Alarm limits............................................................... 76
C
Calibration and Settings........................................... 71
CAN bus settings...................................................... 79
Communication J1939.............................................. 26
Connection............................................................... 50
Connection of special tool VODIA............................ 71
Control System Installation....................................... 50
D
Diagnostic Function.................................................. 92
E
Easy Link Instruments.............................................. 62
Electrical interface.............................................. 11, 13
EMS............................................................................ 5
Engine control interface............................................ 13
Engine protection............................................... 77, 78
Engine protection override....................................... 25
F
Frequency select...................................................... 24
G
General............................................................... 11, 50
Governor mode........................................................ 21
I
Idle switch................................................................. 22
In- and out signals...................................................... 8
Installation Tools and Documentation........................ 4
Instruments......................................................... 10, 67
L
Location of Sensors.......................... 31, 32, 33, 34, 35
O
Other Special Equipment........................................... 4
P
Parameter Setting.................................................... 71
Power down sequence............................................. 17
Power supply............................................................ 51
Power up sequence.................................................. 16
Preheat..................................................................... 23
R
Rpm-potentiometer................................................... 63
S
Safety Information...................................................... 2
Special Tools.............................................................. 4
Synchronizing Engine Speed................................... 70
System Information.................................................... 5
T
Throttle (Synchronizing/Load sharing)..................... 19
Torque speed control............................................... 20
W
Warning and Indication Lamps................................. 65
Wiring Diagram......................................................... 37
47701683 10-2012 © AB VOLVO PENTA 109

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Date:...................................................................
Name:.................................................................
AB Volvo Penta
Service Communication
Avd. 42200
SE-405 08 Göteborg
Sweden
47701683 English 06-2012

EMS2 Installation ManualD16 - US

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Installation I

Industrial Engines 1(1)

47701683 10-2012 © AB VOLVO PENTA 1

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Installation Tools and Documentation

3838619 VODIA, diagnostic 88890074 Multimeter

Other Special Equipment

HDT-48–00 AMP 539 968 AMP 726 519

AMP 726 519 AMP 929 039 AMP 238 635

AMP 825 514 GHW 50000 017 586

4 47701683 10-2012 © AB VOLVO PENTA

CAN (Controller Area Network)

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

47701683 10-2012 © AB VOLVO PENTA 5

CIU (Control Interface Unit)

6 47701683 10-2012 © AB VOLVO PENTA

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

Calculating fuel quantity

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In- and out signals

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There are a number of interfaces available to control

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Engine control interface

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Pin Description Pin Description

There is a cable harness available with all wires con-

1. Not for 124xGE

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Pin Description Pin Description

Connector 2, 12-pole deutsch connector:

Pin Description Pin Description

All indicators shall be less than 3W. All switches are

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16 47701683 10-2012 © AB VOLVO PENTA

Power down sequence

Auto shutdown will power down the system if the igni-

Energized to STOP / RUN

By option or changing a parameter it can be set to

Energized to RUN on Pin5

The main power MUST NOT be switched off before the

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Torque speed control

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Preheating will be terminated immediately if the driver

It is possible for the costumer, using Volvo Penta

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The frequency switch is used for changing the nominal

24 47701683 10-2012 © AB VOLVO PENTA

Engine protection override

Mobile / Versatile / Powerpack

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Identifier Signal name 164xVE 1640-42GE 1643GE 165xVE 166xVE

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Identifier Signal name 164xVE 1640-42GE 1643GE 165xVE 166xVE