520 WS2 PDF
520 WS2 PDF
520 WS2 PDF
Workshop manual
EDC 4
TD420VE, TAD420VE, TD520GE, TAD520GE, TD520VE
TAD520VE, TAD530/531/532GE, TAD620VE, TAD650VE
TAD660VE, TD720GE TAD720GE, TD720VE, TAD720VE
TAD721GE, TAD721VE, TAD722GE, TAD722VE,
TAD730/731/732/733GE, TAD750VE, TAD760VE
Contents
Safety information ................................................. 2
Introduction .......................................................... 2
General information ..............................................
About the workshop manual .................................
Spare parts ..........................................................
Certified engines ..................................................
5
5
5
5
6
6
6
7
7
7
7
26
26
27
27
28
13
13
14
16
20
31
31
31
31
31
31
39
39
39
40
41
42
45
46
22
22
24
24
Group 23 EDC 4
Safety information
Safety information
Introduction
The workshop manual contains descriptions and repair
instructions for products or product versions noted in
the table of contents, supplied by Volvo Penta. Make
sure that you use the correct workshop literature.
Read the available safety information, General Information and Repair Instructions in the workshop
manual before you start to do any service work.
Important
The following special warning signs are used in the
workshop manual and on the engine.
WARNING! Warns for the risk of personal injury,
major damage to product or property, or serious
malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things
which could cause damage or malfunctions to
product or property.
NOTE! Is used to call attention to important information, to facilitate work processes or operation.
To give you a perspective on the risks which always
need to be observed and precautions which always
have to be taken, we have noted them below.
Group 23 EDC 4
If other equipment connected to the engine has
altered its centre of gravity, special lifting devises may be needed to obtain the correct balance
and safe handling.
Never do any work on an engine which just
hangs from a lifting devise.
Never work alone when heavy components are
to be dismantled, even when safe lifting devises
such as lockable blocks & tackle are used.
Even when lifting devises are used, two people
are needed in most cases. One who operates
the lifting devise and other who makes sure that
components move freely and are not damaged
during lifting.
Always make sure that there is enough space
for disassembly where you are working, with no
risk for personal or material damage.
WARNING! Components in the electrical and
fuel systems on Volvo Penta products have
been designed to minimize the risks of explosion and fire. The engine must not be operated
in environments with adjacent explosive media.
Only use the fuels recommended by Volvo Penta. Please refer to the instruction book. The use
of fuel of inferior quality can damage the engine.
In a diesel engine, poor fuel can make the engine over- rev, entailing a strong risk of personal
injury and machinery damage. Poor fuel can
also lead to higher maintenance costs.
Remember the following when washing with a
high pressure washer: Never aim the water jet at
seals, rubber hoses, electrical components or
the radiator.
Always use goggles when doing any work where
there is any risk of splinters, grinding sparks,
acid splash or other chemicals. Your eyes are
extremely sensitive, injury could cause blindness!
Avoid skin contact with oil! Long- term or repeated skin contact with oil can injure your skin. The
consequence is irritation, dry skin, eczema and
other skin disorders. Used oil is more hazardous
to health than new oil. Use protective gloves
and avoid oil-soaked clothes and rags. Wash
regularly, especially before meals. Use special
skin cream to avoid drying and facilitate skin
cleaning.
Safety information
Most chemicals intended for the product, such
as engine and transmission oils, glycol, petrol
(gasoline) and diesel oil, or chemicals for workshop use, such as degreasers, paints and solvents are hazardous. Read the instruction on
the packages carefully! Always observe the
safety advice, e.g. use of breathing protection,
goggles, gloves etc. Make sure that other personnel are not inadvertently exposed to hazardous substances, such as via the air they
breathe. Ensure good ventilation. Handle used
and surplus chemicals in the prescribed manner.
Be very careful when searching for leaks in the
fuel system and testing fuel injectors. Use goggles. The jet which comes from a fuel injector
has very high pressure and considerable penetration ability. Fuel can force its way deep into
body tissue and cause severe injury. Risk of
blood poisoning (septicemia).
All fuels, and many chemicals, are flammable.
Make sure that open flames or sparks can not
set them alight. Petrol (gasoline), some thinners
and hydrogen gas from batteries are extremely
flammable and explosive when mixed with air in
the correct ratio. Do not smoke! Provide good
ventilation and take the necessary precautions
before you start welding or grinding work in the
vicinity. Always have a fire extinguisher easily
available near the workplace.
Make sure that oil and fuel soaked rags, and
used fuel and oil filters are disposed of in a safe
manner. Oil soaked rags can self-ignite in certain circumstances. Used fuel and oil filters are
polluting waste and must be handed to an approved waste management facility for destruction, together with used lubrication oil, contaminated fuel, paint residue, solvents, degreasers
and wash residue.
Batteries must never be exposed to open
flames or electric sparks. Do not smoke close
to the batteries. The batteries generate hydrogen gas when charged, which forms an explosive gas when mixed with air. This gas is very
flammable and highly explosive. A spark, which
can be formed if the batteries are wrongly connected, is enough to make a battery explode
and cause damage. Do not move the connections when you attempt to start the engine (risk
of arcing), and do not stand and lean over one of
the batteries.
Group 23 EDC 4
Safety information
The clutch must be adjusted with the engine
shut off.
The existing lugs on the engine should be used
for lifting the engine/gearbox etc. Always check
that the lifting devices are in good condition and
that they have the correct capacity for the lift
(the weight of the engine plus the gearbox and
extra equipment if installed).
The engine should be lifted with a customized or
adjustable lifting boom for safe handling and to
avoid damaging components on top of the engine. All chains or cables must be parallel to
each other and should be as square as possible
to the top of the engine.
Group 23 EDC 4
General information
General information
About the workshop manual
Certified engines
This workshop manual contains descriptions and repair instructions for the standard versions of following
engines: TD420VE, TAD420VE, TD520GE,
TAD520GE, TD520VE TAD520VE, TAD530/531/
532GE, TAD620VE, TAD650VE TAD660VE,
TD720GE TAD720GE, TD720VE, TAD720VE
TAD721GE, TAD721VE, TAD722GE, TAD722VE,
TAD730/731/732/733GE, TAD750VE, TAD760VE.
The workshop manual can illustrate tasks done on
any of the engines noted above. This means that the
illustrations and photographs which clarify certain details might not entirely correspond. The repair methods are similar in all important respects, however. The
engine designation and number are noted on the type
plate. Please refer to the Engine signs chapter.
The engine designation and number must always be
given in all correspondence about an engine.
The workshop manual has been primarily prepared for
Volvo Penta service workshops and their qualified personnel. This assumes that people who use the
manual have basic skills and can do the tasks of a
mechanical or electrical nature associated with the
trade.
Volvo Penta constantly improves its products, so we
reserve the right to make modifications without prior
notification. All information in this manual is based on
product data which was available up to the date on
which the manual was printed. Any material changes
introduced into the product or service methods after
this date are notified by means of Service Bulletins.
Spare parts
Spare parts for electrical and fuel systems are subject
to various national safety requirements. Volvo Penta
Original Spares comply with these requirements. No
damage whatever, occasioned by use of non-original
Volvo Penta spares for the product, will be compensated by the warranty offered by Volvo Penta.
Group 23 EDC 4
Repair instructions
Repair instructions
The work methods described in the workshop manual
apply to work in a workshop environment. For this reason, the engine is lifted out and mounted on an engine
support. Renovation work which does not need the engine to be lifted out can be done in situ, with the same
work methods, unless otherwise specified.
Please refer to the Safety information chapter, where
the meaning of the warning signs used in the Workshop Manual are explained in detail.
WARNING!
IMPORTANT!
NOTE!
are not comprehensive in any way, since we can not
of course foresee everything, because service work is
done in highly varying circumstances. For this reason,
all we can do is to point out the risks which we believe
could occur due to incorrect work in a well-equipped
workshop, using work methods and tools tested by
us.
In the workshop manual, all tasks for which there are
Volvo Penta special tools, are done using these tools.
Special tools are specially prepared to permit the safest and most rational work methods possible. For this
reason, it is the responsibility of the person who uses
other tools or other work methods than those recommended by us, to ensure that there is no risk of personal injury or material damage, and that they can not
cause any malfunctions.
In some cases, special safety regulations and user instructions are available for the tools and chemicals
mentioned in the workshop manual. These rules must
always be observed, so there are no special instructions about this in the workshop manual.
The majority of risks can be prevented by taking certain elementary precautions and using common
sense. A clean workplace and a clean engine eliminate many risks of both personal injury and malfunction.
Above all, when work on fuel systems, lubrication
systems, inlet systems, turbocharger, bearing caps
and seals is done, it is extremely important that no
dirt or other kinds of foreign particles are able to get
in, since this would otherwise cause malfunctions or
shortened repair life.
Tightening torque
The tightening torques for vital fasteners, which
should be tightened with a torque wrench, are listed in
Technical Data, and are noted in the task descriptions in the manual. All torque specifications apply to
clean screws, screw heads and mating faces. The
torque specifications apply to lightly oiled or clean
screws. If lubricants, locking fluids or sealants are
needed on a fastener, the type of preparation to be
used will be noted in the job description and in Tightening Torques. Where a particular torque value is not
specified for any fastener, the general tightening torques in the table below shall apply. The torque specification is a target value and the fastener does not
need to be tightened with a torque wrench.
Dimension Tightening torque
Nm
lbf.ft.
M5
4.4
M6
10
7.4
M8
25
18.4
M10
50
36.9
M12
80
59.0
M14
140
103.3
Group 23 EDC 4
Repair instructions
Torque-angle tightening
Sealants
Lock nuts
Disassembled locknuts shall not be re-used, they
shall be replaced by new ones, since the locking properties are impaired or lost when the nut is used several times. On locknuts with plastic inserts, such as Nylock, the tightening torque specified in the table
must be reduced if the Nylock nut has the same nut
height as a standard fully metallic hexagonal nut. Reduce the tightening torque by 25% if the screw dimension is 8 mm (0.3") or greater. On Nylock nuts with
higher nut height, where the fully metallic thread is as
high as on a standard hexagonal nut, use the tightening torques in the table.
It is therefore important that the correct types of sealant and locking fluids are used on the fasteners where
needed, to give a fully acceptable service result.
In the workshop manual, the relevant chapters contain
notes on the preparations used in our engine production.
In service work, equivalent preparations of the same
make, or other makes of preparations with directly
corresponding properties shall be used.
When sealants and locking fluids are used, it is important that the surfaces are free from oil, grease, paint,
rust-protection and remains of old sealants. Always
observe the manufacturers instructions about temperatures of use, hardening times and other instructions
for use of the product.
Two basic types of preparation are used on the engine, characteristics are as follows:
Strength classes
Screws and nuts are sub-divided into different
strength classes. The classification is shown by a
marking on the screw head. Markings of a higher
number indicate stronger material. For example, a
screw marked 10-9 is stronger than one marked 8-8.
For this reason, it is important when fasteners are dismantled, that the screws are put back in the correct
places when they are re-installed. When you change
screws, please check the spare parts catalogue to ensure that the correct versions are obtained.
Group 23 EDC 4
General
Engine signs
Location of engine signs
The engines are supplied with two engine signs, of
which one is installed on the right side of the engine
block.
Engine plate
1.
2.
3.
4.
5.
6.
7.
Engine model
Engine specification number
Engine series number (10 digits)
Engine power, peak, without fan
Engine speed
Injection advance and type of camshaft
Manufacturers identification code
Group 23 EDC 4
Tools
Special tools
The following special tools are used in work on engines. Special tools can be ordered from Volvo Penta under the
part numbers given below.
999 9324
951 0060
999 8482
3838619
951 2636
Tools
Designation use
999 8482
Template, connector
999 9324
951 2636
951 0060
1078054
885675
3838619
VODIA
HDT-48-00
0411-310-1605
Deutsch connectors
HDT-48-00
725 938-0
Dissasembly tool
0411-310-1605
Dissasembly tool
825 582-2
726 534-1
726 519-1
825 514-1
825 514-1
872 070-1
734 289-2
Group 23 EDC 4
Technical data
Technical data
Control unit
Voltage .................................................................. 24 V or 12 V (engine can be started from 6 V)
Connector .............................................................. 2 x 25-pin (AMP)
Max cable length .................................................... 5 m (16,4 ft)
Working range, temperature ................................... -40 C (-40.0F) to +85 C (185.0F)
Current drain (incl. actuator) ................................... <9 A, <11.5 A for 60 s (12 A fuse)
Weight ................................................................... 1.6 kg (3.5 lb)
Size (L x W x H) .................................................... 231 x 204 x 62 mm (9 x 8 x 2.4)
Relative humidity ................................................... < 98% (at 55 C (131.0F))
Protection class ..................................................... IP 66k, IP X7, IP X9k to DIN40050
Impact tolerance .................................................... < 50 g (0,1 lb)
Vibration ................................................................ < 1.5 mm (0.06") (at 10 20 Hz)
< 180 mm/s (7.01" /s) (at 21 63 Hz)
< 7 g (at 64 2000 Hz)
Housing .................................................................. Cast, untreated aluminum
Diagnostic interface ............................................... Serial interface SAE J1708
Computer interface ................................................. CAN-Bus with ISO/DIS 11989, SAE J1939 protocol
Electromagnetic comparability ............................... Radiated interference 95/54/EWG
Interference immunity up to 100 V/m ISO 11452-2, ISO 7637,
TR 10605
Load dumping ........................................................ U < 60 V
Actuator
Connector .............................................................. 5 pin
Resistance, control solenoid .................................. app. 1.3
Resistance, measurement solenoid ....................... app. 25.4
Resistance, reference solenoid .............................. app. 25.3
Inductance, measurement solenoid ........................ app. 21.5 mH (stop position)
app. 8.1 mH (full throttle position)
Inductance, reference solenoid .............................. app. 13.3 mH (constant)
Speed sensor, camshaft
Connector .............................................................. 2 pin
Working range, engine speed ................................. 30 rpm to 4500 rpm
Working range, temperature ................................... -40 C (-40.0F) to +85 C (185.0F)
Resistance ............................................................. 336 W 34 W at 23 C
Inductance ............................................................. 128.8 mH 13mH at 1kHz and 23 C (73,4 F)
Lowest voltage () .................................................. 150mV peak to peak at 2 mm (0.08") air gap and 30 rpm
Type ...................................................................... Inductive sensor
Max. tightening torque ............................................ 9 Nm (6.6 lbf-ft)
10
Group 23 EDC 4
Technical data
11
Group 23 EDC 4
Oil pressure sensor
Voltage .................................................................. 5 V 0.25 VDC
Connector .............................................................. 3 pin
Working range, pressure: ....................................... 0 -1000 kPa (0-145.0 psi)
Pressure signal ...................................................... 0.5 -4.5 VDC
Type ...................................................................... Linear
Max. tightening torque ............................................ 45 Nm (33.1 lbf-ft)
Fuel temperature sensor
Connector .............................................................. 2 pin
Working range, temperature ................................... -40 C (-40.0F) to +140 C (284.0F)
Rated voltage ......................................................... 5 0.15 VDC
Characteristic ........................................................ -40 C (-40.0F)
45313
0 C (32.0F)
5896
23 C (73.4F)
2057
60 C (140.0F)
596
100 C (212.0F)
186
140 C (284.0F)
71
Type ...................................................................... NTC* (Negative Temperature Coefficient)
Max. tightening torque ............................................ 20 -24 Nm (14.7-17.7 lbf-ft)
12
Technical data
Group 23 EDC 4
Summary
Diagnostic function
The system includes sensors, control unit and an engine speed regulator. The sensors send input signals
to the control unit, which controls the control rod for
the injection pumps in its turn, by means of an actuator in the engine speed regulator.
Input signals
The control unit receives input signals about engine
operating conditions from the following components:
Output signals
The control unit controls the following components on
the basis of the input signals received:
Information from the sensors provides exact information about current operation conditions and allows the
processor to calculate the correct fuel volume, check
engine status etc.
13
Group 23 EDC 4
Other functions
The EDC4 system contains a number of functions
whose functions include engine protection.
Droop
Smoke limiting
Stability
The engine speed regulator can be adjusted by means
of the VODIA tool, to trim the engine for a number of
different applications. Please refer to the Fine adjustment, engine speed regulator chapter.
If there is any fault in the signal from the accelerator pedal, the engine speed is set to 1200 rpm (socalled limp home speed).
NOTE! Only applies to VE engines.
Idling
Altitude correction
14
Group 23 EDC 4
Cold starting
The control unit controls engine speed increase during a
cold start. The control unit limits the number of rpm that
engine speed can increase per second.
Example: For VE engines at -30C (-22.0F) , engine
speed can not increase by more than 100 rpm per second (units: r/min/s), please refer to the diagram below.
VE engines:
When coolant temperature is between -30 C (-22.0F)
and +10 C (50.0F) , the control unit increases engine
speed as in the diagram below.
GE engines:
When coolant temperature is between -30 C (-22.0F)
and 0 C (32.0F) , the control unit increases engine
speed as in the diagram below.
15
Group 23 EDC 4
Component description
The numbers after the headings refer to the Component location chapter.
engine speed
charge air pressure
coolant temperature
fuel temperature
oil pressure
coolant level (option)
The information provides exact information about current operation conditions and allows the processor to
calculate the correct fuel volume, check engine status etc.
16
Group 23 EDC 4
17
Group 23 EDC 4
18
Group 23 EDC 4
Alternator
The alternator is belt driven and is located at the front
of the engine.
The voltage regulator on the alternator is provided
with a sensor system. The sensor system compares
the charge voltage across the alternator terminals, B+
and B-, with the current voltage across the positive
and negative battery terminals. The voltage regulator
then compensates for any voltage drop in the cables
between the alternator and the battery, by increasing
the charge voltage supplied by the alternator as necessary.
Starter motor
The starter motor is installed on the flywheel housing,
on the left-hand side of the engine.
When engaged, a gear wheel is first slid axially along
the starter motor rotor spindle, so that it engages on
the gear ring on the engine flywheel. The axial movement of the gear, and connection of the starter motor,
are controlled by an actuator solenoid on the starter
motor.
The starter motor solenoid is engaged via the starter
relay in its turn, which is activated when the starter
key is turned to position III or the start button is depressed.
19
Group 23 EDC 4
Component location
20
Group 23 EDC 4
Limit values
Limit values
These functions are customer parameters and can be shut off completely.
NOTE! The diagnostic lamp flashes when the alarm limit is reached, even if the function is shut off.
Alarm limits:
Coolant temperature:
Engine is stopped
110 C (230.0F)
(goes out at 109C (228.1F))
113 C (235.4F)
after 30 sec.
Coolant level:
The control unit does not check this function until 25 s after starting. When the control unit receives a low coolant
level signal, the engine is shut off after 5 sec.
Oil pressure:
The control unit does not check this function until 30 s after starting.
The limit values depend on engine speed. The diagnostic lamp lights up when the limit value is reached, and goes
out again when the oil pressure has risen 10% above the limit value. The engine is shut off when oil pressure falls
to 80% of the limit value.
Engine is stopped
21
Group 23 EDC 4
Parameter setting
Parameter setting
Adjustable parameters
The VODIA tool can be used to read and adjust the
parameters below, in Parameter Programming mode:
Please refer to the VODIA Users Guide for advice
on use.
NOTE! Special authorization is needed to be able to
adjust certain parameters.
Idling speed voltage error
Full throttle voltage
Voltage at the throttle control input which corresponds
to full throttle.
A fault code is set if the signal falls below the minimum value.
Min. value
0V
Min. value
0V
Default value
0.1 V
Default value
4.6 V
Max. value
5V
Max. value
5V
Idling speed.
Min. value
0 r/min
Min. value
0V
Default value
700 r/min
Default value
4.9 V
Max. value
4000 r/min
Max. value
5V
Idle voltage
Voltage at the throttle control input which corresponds
to idling.
Min. value
0V
Default value
0.3 V
Max. value
5V
22
Group 23 EDC 4
Parameter setting
Min. value
0%
Default value
VE: 10 %, GE: 30 %
Max. value
100 %
Default value: On
0%
Default value
VE: 50 %, GE: 85 %
Max. value
100 %
0%
Default value
VE: 4 %, GE: 3 %
Max. value
100 %
Droop
Selects the amount of droop to be used.
Min. value
0%
Default value
5%
Max. value
100 %
Potentiometer
CAN
Both
CAN communication (special authorization needed)
VE engines: On
GE engines Off
Control rod
(Special authorization needed)
Control rod calibration.
Min. value
0 mm (0)
Max. value
20 mm (0.7874")
23
Group 23 EDC 4
Read-only parameters
The VODIA tool can be used to read and the values
below, in Log test mode: Please refer to the VODIA
Users Guide for advice on use.
Battery voltage
Coolant temperature
Oil pressure
Fuel temperature
Engine speed
Accelerator linkage %
Droop %
Engine loading %
Parameter setting
24
Group 23 EDC 4
Parameter setting
Adjustment
1. Use the VODIA tool and note the current values of
the P, I and D sections of the PID regulator.
rpm
Demanded engine speed
time
rpm
True
enginevarvtal
speed
Verkligt
time
Fig 4. I section too high or D section too low
rpm
Demanded engine speed
rpm
Demanded engine speed
time
time
Fig 1. P section too low
rpm
rpm
Load removal
Demanded engine speed
Load application
time
time
Fig 6. Demanded response
25
Group 23 EDC 4
Repair instructions
Repair instructions
Working on the EDC4 system
Follow the instructions below, to avoid damage to the EDC4 system control unit.
Never turn off the main switch when the engine is running.
When the batteries are quick charged, turn the main switch off or undo the battery cables.
During normal maintenance charging, the main switch does not need to be turned off.
Only batteries may be used for start help. Quick starting units can give excess voltages and damage the control module.
Disconnect the EDC4 system from system voltage before undoing either of the 25 pin connectors on the control unit.
If you discover any damage on the cable harnesses, undo the connector on the control unit.
IMPORTANT! Always undo the connectors on the control unit before doing any welding.
26
When a connector is undone from a sensor, be careful to ensure that the connector pins are not exposed to
oil or other fluids. The consequence of this can be contact problems, or if oil runs down onto the pressure
sensing diaphragm, the sensor will indicate an incorrect value.
Group 23 EDC 4
Repair instructions
27
Group 23 EDC 4
28
Repair instructions
Group 23 EDC 4
Function check
Function check
Diagnostic function for VODIA (including Penta EDC 4 software)
The program can read fault codes which have been stored in the engine control unit, check input and output
signals, read off current values from engine sensors, and then store and print out test results.
The program allows service and workshop personnel to quickly localize and attend to faults in the EDC4 system.
It is connected to the engine control unit via a diagnostic connector (VODIA input), please refer to the Wiring
schedule chapter.
If a malfunction is found, the diagnostic indicator in the control panel begins to flash. A diagnostic trouble
code (DTC) can be obtained by pressing the diagnostic button, as a guide for any fault-tracing.
Please refer to the VODIA Users Guide for more information and advice on use.
29
Group 23 EDC 4
Function check
Fault tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer if any problems occur which you can not solve by yourself.
WARNING! Read through the safety advice for care and maintenance work in the Safety information chapter before starting work.
2, 4
1, 2, 3, 4, 5, 6, 7, 24
1, 2
8, 9, 10, 11
8, 9, 10, 11, 13
10, 11, 27
12, 13
14, 15, 22
16
20
2, 23
1. Flat batteries
30
8. Lack of fuel:
- fuel taps closed
- fuel tank empty/wrong tank
connected
Group 23 EDC 4
Diagnostic function
Diagnostic function
The diagnostic function monitors and checks that the
EDC 4 system functions normally.
Effect on engine
Malfunction message
If the diagnostic function discovers a malfunction in
the EDC 4 system, this is notified via the CAN bus or
the diagnostic lamp lights up or starts to flash. At the
same time, the fault is stored in the control unit memory. As soon as the fault has been attended to and the
ignition is turned off and on, the fault code lamp goes
out. Both rectified (passive) and un-rectified (active)
faults are stored in the control unit and can be read by
an authorized workshop.
Operation
During starting
When the ignition is turned on, the diagnostic lamp
lights up for two seconds, together with the warning
lamps for oil pressure and coolant. This is to check
the lamp function.
If the diagnostic lamp flashes after the two seconds,
this indicates a serious fault and the engine can not
be started. One or more fault codes can then be
flashed out.
If the diagnostic lamp is lit, there are one or more less
serious faults. One or more fault codes can then be
flashed out.
31
Group 23 EDC 4
During operation
If the diagnostic lamp starts to flash during operation:
1. Reduce engine speed to idling.
2. Press the diagnostic button (for 1-3 seconds).
3. Release the diagnostic button and make a note of
the diagnostic trouble code (DTC) that is flashed
out. Please refer to Reading fault codes below.
4. Look up the fault code in the fault code list and
take the necessary measures. Please refer to the
Fault codes chapter.
If the diagnostic lamp starts to flash, the engine will
be emergency stopped.
IMPORTANT! In VE engines, there is a function
in the system which makes it possible to start
the engine again and run it for about 25 seconds. This is so that the vehicle can be moved
from a railway level crossing etc.
Diagnostic function
(2 long) pause
The VODIA tool (including the Penta EDC4 software). Please refer to the VODIA Users Guide
for advice on use.
Diagnostic lamp
CAN
Diagnostic lamp
If the diagnostic lamp is illuminated or flashes, a fault
code can be read by pressing the diagnostic button
(for 1-3 seconds) and then releasing it. The diagnostic
lamp goes out, and a fault code is then flashed out.
32
Group 23 EDC 4
Fault codes
Fault codes
WARNING! Read through the safety advice for care and maintenance work in the Safety information chapter before starting work.
PID 190, Code 2.1.4 Overspeed
33
Group 23 EDC 4
Fault codes
Action:
Action:
Reason: Oil pressure below specified limit value (depends on engine speed).
Reaction: A fault code is generated. The fault code disappears when the oil pressure exceeds the recuperation value.
Action:
34
Group 23 EDC 4
Fault codes
Reaction: A fault code is generated. The fault code disappears when the fuel temperature falls below the recuperation value.
Action:
Action:
Action:
35
Group 23 EDC 4
Fault codes
Turn the ignition off and on, and check if the fault
code remains.
36
Group 23 EDC 4
Fault codes
Turn the ignition off and on, and check if the fault
code remains.
Turn the ignition off and on, and check if the fault
code remains.
Turn the ignition off and on, and check if the fault
code remains.
Turn the ignition off and on, and check if the fault
code remains.
Action:
Turn the ignition off and on, and check if the fault
code remains.
Action:
Turn the ignition off and on, and check if the fault
code remains.
37
Group 23 EDC 4
PID 48, Code 2.9.2 Atmospheric pressure
Reason: Air pressure is outside permissible values.
Reaction: A fault code is generated. The fault code disappears when the pressure returns to normal. Monitoring
function for air pressure is de-activated.
Action:
Turn the ignition off and on, and check if the fault
code remains.
Turn the ignition off and on, and check if the fault
code remains.
38
Turn the ignition off and on, and check if the fault
code remains.
Fault codes
Group 23 EDC 4
Fault codes
Coolant level
Air filter
Battery
Cables (visual)
Main switch, circuit breakers, connectors
Relay connections
Check the wiring schedule to ensure that measurement is done at the correct place.
Use multimeter 9510060 to measure the cables.
NOTE! Never do measurements by poking a probe
through insulation.
Check all measurements against the data read from
the wiring schedule.
Actuator
Contact problems
39
Group 23 EDC 4
Open circuit
Carefully insert gauge 9998482 into the connectors. Pull the gauge back and forwards a few
times, and feel whether the connectors grip the
gauge. If the connectors have lost their grip, or if
they are weak, change the spade terminals.
Please refer to the Joining electrical cables for
multi-connector chapter.
Use multimeter 9510060-8 to measure the resistance between the ends of the cable. Nominal value R ~ 0 .
Shake cables if possible, and pull connectors during measurement, to find where the cable is damaged.
Important! The engine management unit connector must only be checked by means of gauge
9998482.
Shake cables if possible, and pull connectors during measurement, to find where the cable is damaged.
40
Group 23 EDC 4
41
Group 23 EDC 4
NOTE! There are two different types of charge pressure sensors. A 3-pin and a 4-pin sensor.
1.
2.
3.
4.
Measure, with the multimeter set to voltage measurement. Check that the multimeter indicates 5.0
Volt.
5.
42
Group 23 EDC 4
Temperature
The same type of sensor is used for both coolant temperature and fuel temperature.
1.
2.
3.
-20 C (-4.0F)
-10 C (14.0F)
0 C (32.0F)
10 C (50.0F)
20 C (68.0F)
23 C (73.4F)
30 C (86.0F)
40 C (104.0F)
50 C (122.0F)
60 C (140.0F)
70 C (158.0F)
80 C (176.0F)
Resistance
15462
9397
5896
3792
2500
2057
1707
1175
834
596
435
323
43
Group 23 EDC 4
In a visual check, first remove the sensor from the engine. Then undo the connector and check that the sensor is undamaged, and that no swarf has stuck on the
sensor.
1.
2.
2.
3.
3.
Set multimeter 9510060-8 to resistance measurement. Use the multimeter to measure between the
engine speed sensor pins. The multimeter should
show 336 34
4.
Measure, with the multimeter set to voltage measurement. Check that the multimeter indicates
5.0 Volt.
5.
Then connect the multimeter between measurement points 1-2. The voltage should be about
0.5 V.
4.
44
Group 23 EDC 4
2.
3.
Set multimeter 9510060-8 to resistance measurement. Use the multimeter to measure the 5pin connector on the engine speed regulator, between:
Pin
Resistance
1 - 2 app. 1.3
3 - 4 app. 25.4
3 - 5 app. 25.3
2.
3.
Carbon brushes
The specification for the carbon brushes in the starter motor is described below.
Carbon brush condition
New = 23 mm (0.90551")
Change at = 13 mm (0.51181")
45
Group 23 EDC 4
2.
3.
46
Group 23 EDC 4
Brushes
Measure the length of the brushes between the brush
mating surface and the brush holder. If the dimension
of the projecting part is less than 5 mm (0.20") , or if
any brush is damaged, it should be changed.
5 mm (0,197 inch)
NOTE! Make sure that the solder bead on the soldered joint does not penetrate too far along the brush
lead. This would make the lead stiff, and could obstruct movement.
Regulator
Checking the regulator:
1.
2.
3.
4.
47
Group 23 EDC 4
2.
3.
4.
5.
48
Group 23 EDC 4
2.
3.
4.
5.
49
Group 23 EDC 4
2.
3.
4.
5.
50
Group 23 EDC 4
2.
3.
Do three measurements.
4.
2.
3.
51
Group 23 EDC 4
2.
3.
4.
2.
3.
52
Group 23 EDC 4
Electrical system
Electrical system
Warning! The battery locker must never be exposed to open flames or electric sparks. Do not
smoke close to the batteries. The batteries generate hydrogen gas when charged, which forms
an explosive gas when mixed with air. This gas
is very flammable and highly explosive.
Main switch
Never cut the circuit between the alternator and
the batteries when the engine is running. The
main switch(es) must never be disconnected before the engine has been stopped.
If the circuit is broken when the engine is running,
the voltage regulator can be destroyed and the alternator can be seriously damaged.
The charging circuits must never be re-connected
with the engine running, for the same reason. A
Volvo Penta charge splitter (optional) can be installed on the standard alternator to charge two
independent battery circuits.
2.
Batteries
Never mix up the battery positive and negative
poles when the batteries are installed.
If the batteries are wrongly connected, this can
cause severe damage to the electrical equipment.
Please check the wiring diagram! The battery
poles should be carefully cleaned, the terminals
should always be tightened and thoroughly
greased.
Avoid quick charging the batteries. If quick charging has to be employed, the ordinary battery cables must always be disconnected first.
4.
Electric welding
Remove the positive and negative cables from the
batteries. Then disconnect all connections to the alternator.
Disconnect the cable connectors from the control unit.
Please refer to Control unit, changing.
Always connect the welder earth clamp to the component to be welded, and as close as possible to the
weld site. The clamp must never be connected to the
engine or in such a way that current can pass through
a bearing.
Important! When welding is finished, the disconnected components such as connectors, alternator cables and battery cables must be reinstalled in the correct order.
53
Group 23 EDC 4
Electrical system
Wiring diagram
Wiring diagrams, engine side
A.
B.
C.
D.
E.
F.
G.
H.
J.
K.
L.
54
Earth (ground)
Digital output signal
Digital output signal 4
Input signal 1, temperature NTC
Input signal 2, temperature NTC
Digital input signal 5
Digital output signal 7
Earth (ground)
Analogue input signal 3
Earth (ground)
Input signal, engine speed 2
Earth (ground)
Input signal, engine speed 1
PWM output signal control solenoid
(STG -)
PWM output signal control solenoid
(STG +)
Shielded cable
Common connection for reference and
control rod measurement RF
RF Ref
RF Meas.
Earth (ground)
Analogue input signal 4
+ 5 V reference voltage
Earth (ground)
Analogue input signal 2
+5 V
Group 23 EDC 4
Electrical system
Wiring diagrams,
engine side
F
Signal description, control unit,
connector F
#1. Ubatt (-)
#2. Earth (ground)
#3. Digital output signal 2, warning lamp for
coolant temperature
#4. Digital output signal 5, diagnostic lamp
#5.
#6.
#7.
#8. J1708A
#9. J1708B
#10.
#11.
#12. CAN high
#13. CAN low
#14. Ubatt (+)
#15. Digital output signal 6, warning lamp for
oil pressure
#16. Digital output signal 8 (frequency)
tachometer
#17. Earth (ground)
#18. Digital input signal 1, 1500/1800 rpm
switch
#19.
#20.
#21. Digital input signal 2, droop contact
#22. Shielded cable
#23. Earth (ground) for SWG, potentiometer
#24. Analogue input signal 1, potentiometer
#25. + 5 V reference voltage, potentiometer
Battery (+30)
J1708B
Battery (-)
J1708A
55
Notes
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56
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AB Volvo Penta
Customer Support
Dept. 42200
SE-405 08 Gothenburg
Sweden
7745232
English 06-2007