Volvo Penta D6 Group 30 Electrical system Workshop and Repair Manual [en]

Workshop Manual Group 30 Electrical system B 2(0) Volvo Penta IPS EVC-C

Group 30 Electrical system Marine Diesel engines IPS 350 • IPS 400 • IPS 500 • IPS 600 D4-260D-B • D6-310D-B • D6-370D-B • D6-435D-A Safety information ................................................ 4 Introduction ......................................................... 4 Important ............................................................ 4 General information ............................................. 7 About this Workshop Manual .............................. 7 Spare parts ......................................................... 7 Certified engines ................................................. 7 Repair instructions ............................................... 8 Our common responsibility .................................. 8 Tightening torques .............................................. 8 Special tools ........................................................ 9 Design and function ............................................. 10 System description EDC7 ...................................... 10 EVC system .......................................................... 11 Component location ............................................ 13 Component description ........................................... 17 PCU .................................................................... 17 SHCU ................................................................. 17 SUS .................................................................... 17 Identification of the PCU and SHCU .................... 18 Control ................................................................ 19 Solenoid valves, transmission ............................ 19 Resolver ............................................................. 20 Starter motor ....................................................... 20 Alternator ............................................................ 20 Injectors .............................................................. 21 Sensor, engine speed (flywheel) .......................... 21 Sensor, camshaft position .................................. 21 Sensor, boost air pressure/ boost air temperature .......................................... 22 Sensor, lube oil pressure, engine ........................ 22 Coolant temperature sensor ................................ 23 Fuel temperature sensor ..................................... 23 Sensor, common rail pressure (fuel) .................... 23 Contents Magnetically controlled proportional valve (MPROP) ................................ 24 Supercharger ...................................................... 24 Water switch, secondary fuel filter ...................... 24 Engine control unit, EDC7 ................................... 25 Switch, coolant level ........................................... 25 Extra stop button ................................................ 26 Fuses ................................................................. 26 Voltage converter DC/DC, 12 V ........................... 26 Repair instructions ............................................... 27 General advice on working with EVC engines ........ 27 Electric welding ...................................................... 27 Fault tracing of cables and connectors ................... 28 Fault tracing of the starter motor and windings ....... 29 Rail pressure measurements .................................. 30 Changing the engine control unit ............................ 31 Identifying the engine control unit ........................ 32 Reprogramming the control unit ........................... 33 Programming an empty control unit ..................... 34 Malfunctions ......................................................... 34 Fault code information ......................................... 34 FMI table ............................................................ 34 SAE standard ..................................................... 34 General advice .................................................... 35 System introduction, EVC ................................... 36 Starting sequence ............................................... 36 Network ............................................................... 37 Manual fault tracing in bus cables ....................... 37 Fault tracing the EVC system ............................. 38 Checking the instruments ................................... 39 Alarm display ...................................................... 40 Time delay on alarm indication ............................ 40 Coolant level monitor .......................................... 41 Measurements .................................................... 42 Checking the coolant monitor .............................. 43

Contents Group 30: Electrical system 2 Diagnostic Trouble Codes ................................... 44 MID 128, PID MID 128, PID 91 Throttle control position ......... 44 MID 128, PID 97 Water switch, fuel filter .......... 46 MID 128, PID 100 Oil pressure sensor ............... 49 MID 128, PID 105 Boost air temperature sensor ................................... 56 MID 128, PID 106 Boost air pressure sensor ...... 61 MID 128, PID 108 Atmospheric pressure sensor 67 MID 128, PID 110 Coolant temperature sensor .. 69 MID 128, PID 158 Battery voltage ...................... 74 MID 128, PID 164 Fuel pressure ......................... 77 MID 128, PID 174 Fuel temperature sensor ........ 83 MID 128, PID 190 Engine speed, excess speed / calculation .... 88 MID 128, SID MID 128, SID 1/2/3/4/5/6 Injectors 1–6 .................. 93 MID 128, SID 21 Camshaft position sensor (speed sensor, camshaft) ...... 96 MID 128, SID 22 Speed sensor (flywheel) ......... 100 MID 128, SID 26 Output, compressor coupling . 104 MID 128, SID 40 Output, starter motor ............. 107 MID 128, SID 57 Output, fuel pump (MPROP), fault ....................................... 110 MID 128, SID 218 ECM main relay ..................... 114 MID 128, SID 231 SAE J1939 Data link ............. 116 MID 128, SID 251 Supply voltage ....................... 118 MID 128, SID 254 Engine control unit EDC7 ....... 119 MID 128, PSID MID 128, PSID 50 Fuel pressure, monitoring (MPROP) ............................... 120 MID 128, PSID 51 Redundant Shut-off Path ....... 127 MID 128, PSID 53 Monitoring the pressure relief valve ............................. 128 MID 128, PSID 54 Booster voltage (high bank 1) 130 MID 128, PSID 55 Booster voltage (high bank 2) 132 MID 164, PPID MID 164, PPID 390 Lever 1 position relative to potentiometer supply failure ... 134 MID 164, PPID 391 Lever 2 position relative to potentiometer supply failure ... 140 MID 164, PPID 392 Lever potentiometer supply failure ......................... 142 MID 164, PPID 393 Data bus power input ............. 239 MID 164, PPID 394 Key supply ............................ 144 MID 164, PPID 397 Main panel communication failure .................................... 147 MID 164, PPID 424 Steering wheel position .......... 245 MID 164, SID MID 164, PSID139 Auto pilot fault ....................... 150 MID 164, SID 226 Neutral switch and lever position mismatch ................. 152 MID 164, SID 231 Sync bus communication fault ....................................... 155 MID 164, SID 240 Program memory fault ........... 210 MID 164, SID 250 SAE J1708 / J1587 data link . 157 MID 164, SID 253 Calibration Memory Failure .... 211 MID 164, SID 254 Internal CPU faults ................ 214 MID 164, PSID MID 164, PSID 64 Joystick fault ......................... 159 MID 164, PSID 65 Joystick on-button ................. 161 MID 164, PSID 66 Joystick hi-button .................. 162 MID 164, PSID 67 Joystick sync fault ................ 163 MID 164, PSID 95 Lever detection ...................... 164 MID 164, PSID 96 Calibrated lever travel too small ................................ 166 MID 164, PSID 97 Lever calibration procedure .... 167 MID 164, PSID 98 Lever(s) not calibrated ........... 168 MID 164, PSID 99 Data bus network configuration fault ....................................... 237 MID 164, PSID 103 Neutral button ........................ 169 MID 164, PSID 104 Lighting button (multifunction button) ............. 171 MID 164, PSID 105 Active station button .............. 173 MID 164, PSID 106 Start ...................................... 175 MID 164, PSID 107 Stop ....................................... 177 MID 164, PSID 133 Steering wheel data link ......... 179 MID 164, PSID 134 Steering wheel module ........... 181 MID 164, PSID 135 Steering wheel brake ............. 182 MID 164, PSID 136 Steering wheel controller ........ 183 MID 164, PSID 137 Rudder angle ......................... 184 MID 164, PSID 138 Steering position divergence .. 186 MID 164, PSID 140 Incompatible sync bus version ............................ 187 MID 164, PSID 218 Data bus passive / active helm communication failure ............ 188 MID 164, PSID 226 SHCU communication failure with other helm ...................... 190 MID 164, PSID 231 Incompatible Chassie ID ........ 192 MID 164, PSID 232 Data bus communication warning .................................. 234

Group 30: Electrical system Contents 3 MID 187, PID MID 187, PID 96 Fuel level ............................... 192 MID 187, PID 127 Transmission oil pressure sensor ................................... 196 MID 187, PID 177 Transmission oil temperature . sensor ................................... 200 MID 187, PPID MID 187, PPID 393 Data bus power input ............. 239 MID 187, PPID 400 Transmission sensor supply .. 203 MID 187, SID MID 187, SID 231 J1939 Communication warning / fault ........................ 206 MID 187, SID 240 Program memory fault ........... 210 MID 187, SID 253 Calibration Memory Failure .... 211 MID 187, SID 254 Internal CPU faults ................ 214 MID 187, PSID MID 187, PSID 10 Incompatible engine type ....... 215 MID 187, PSID 17 Data bus network configuration fault ....................................... 237 MID 187, PSID 18 Data bus power output ........... 216 MID 187, PSID 20 Primary solenoid (high side switch) ................... 219 MID 187, PSID 22 Secondary solenoid (high side switch) ................... 223 MID 187, PSID 32 Data bus communication with active helm failure ................. 225 MID 187, PSID 200 No data on engine bus ........... 228 MID 187, PSID 226 SHCU communication failure with other helm ...................... 231 MID 187, PSID 231 Incompatible Chassie ID ........ 192 MID 187, PSID 232 Data bus communication warning .................................. 234 MID 250, PID MID 250, PID 168 Battery input .......................... 242 MID 250, PPID MID 250, PPID 55 ECU temperature ................... 249 MID 250, PPID 393 Data bus power input ............. 239 MID 250, PPID 424 Steering wheel position .......... 245 MID 250, PPID 426 Rudder angle ......................... 247 MID 250, PPID 427 Servo motor temp. ................. 250 MID 250, SID MID 250, SID 240 Program memory fault ........... 210 MID 250, SID 253 Calibration Memory Failure .... 211 MID 250, SID 254 Internal CPU faults ................ 214 MID 250, PSID MID 250, PSID 1 Data bus network configuration fault ....................................... 237 MID 250, PSID 2 Data bus power output ........... 252 MID 250, PSID 3 Servo motor ........................... 254 MID 250, PSID 4 Electro mechanical rudder brake .......................... 259 MID 250, PSID 6 Data bus communication with active helm failure .......... 262 MID 250, PSID 232 Data bus communication warning .................................. 234 Wiring diagrams ................................................... 266 Engine D4, D6 ..................................................... 266 Controls .............................................................. 268 Pin configuration, PCU ........................................ 269 Pin configuration, SHCU ..................................... 270 Calibration before start ........................................ 271 General ............................................................... 271 Calibration mode ................................................. 272 Auto configuration ............................................... 272 Combinations of control levers for EVC. Summary, calibration .......................................... 274 Lever calibration ..................................................... 276 Idling speed calibration ........................................... 278 Checking the charging system ............................ 279 Technical data ...................................................... 281 References to Service Bulletins .......................... 283 Index ..................................................................... 284 © 2006 AB VOLVO PENTA We reserve the right to make modifications without prior notice. Printed on environmentally compatible paper.

4 Safety information Introduction This workshop manual contains technical data, descriptions and repair instructions for the Volvo Penta products or product versions noted in the table of contents. Check that you have the correct Workshop Manual for your engine. Read the available safety information, “General information” and “Repair instructions” in the workshop manual before you start to do any service work. Important In this book and on the product you will find the following special warning symbols. 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. Below is a summary of the risks involved and safety precautions you should always observe or carry out when operating or servicing the engine. Make it impossible to start the engine by cutting system current with the main switch(es) and lock it (them) in the off position before starting service work. Set up a warning notice by the helm station. As a general rule all service operations must be carried out with the engine stopped. Some tasks, such as adjustments, need the engine to be running, however. Approaching an engine which is operating is a safety hazard. Remem- ber that loose clothing or long hair can fasten in rotating parts and cause serious personal injury. If work is done adjacent to a running engine, a careless movement or a dropped tool can lead to personal injury in the worst case. Take care to avoid contact with hot surfaces (exhaust pipes, turbocharger, air intake pipe, starter heater etc.) and fluids in pipes and hoses in an engine which is running or has just been stopped. Reinstall all protective parts removed during servicework before starting the engine. Never start the engine with the valve cover removed. Apart from the risk of spilling oil, there is a risk of personal injury. The voltage supplied to the injectors can be as high as 80 V. Check that the warning or information labels on the product are always clearly visible. Replace labels which have been damaged or painted over. Never start the engine without installing the air cleaner filter. The rotating compressor turbine in the turbocharger can cause severe injury. For- eign objects entering the intake ducts can also cause mechanical damage. Never use start spray or similar products as a starting aid. They may cause an explosion in the inlet manifold. Danger of personal injury. Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out and the system pressure will be lost. Open the filler cap slowly, and release the pressure in the cooling system if the filling cap or tap has to be opened, or if a plug or coolant hose has to be removed when the engine is hot. It is difficult to anticipate in which direction steam or hot coolant can spray out. Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before carrying out any work. Never start or operate the engine with the oil filler cap removed, otherwise oil could be ejected. Stop the engine and close the sea cocks before doing any work on the cooling system.

Group 30: Electrical system Safety information 5 Only start the engine in a well-ventilated area. When operated in a confined space, exhaust fumes and crankcase gases must be ventilated from the engine bay or workshop area. Always use protective glasses or goggles when carrying out work where there is a risk of splin- ters, grinding sparks, acid splashes or where other chemicals are used. Your eyes are extremely sensitive, injury could cause blindness! Avoid getting oil on your skin! Repeated exposure to oil or exposure over a long period can result in the skin becoming dry. Irritation, dryness and eczema and other skin problems can then occur. Used oil is more dangerous than fresh oil from a health aspect. Use protective gloves and avoid oil- soaked clothes and rags. Wash regularly, espe- cially before eating. There are special skin creams which counteract drying out of the skin and make it easier to clean off dirt after work is completed. Most chemicals intended for the product (e.g. engine and transmission oils, glycol, petrol (gasoline) and diesel oil) or chemicals for workshop use (e.g. degreasers, paints and solvents) are hazardous. Read the instructions on the product packaging with care! Always follow the safety precautions for the product (for example use of protective mask, glasses, gloves etc.). Make sure that other personnel are not inadvertently exposed to hazardous chemicals, for example in the air. Ensure good ventilation in the work place. Follow the instructions provided when dis- posing of used or leftover chemicals. Exercise extreme care when leak detecting on the fuel system and testing the fuel injector noz- zles. Use eye protection. The jet which comes from a fuel injector has very high pressure and considerable penetrationability. Fuel can force its way deep into body tissue and cause severe injury. Danger of blood poisoning (septicemia). All fuels, and many chemicals, are flammable. Do not allow naked flame or sparks in the vicini- ty. Petrol (gasoline), some thinners and hydrogen gas from batteries are extremely flammable and explosive when mixed with air in the correct ratio. No smoking! Ensure that the work area is well ventilated and take the necessary safety precautions before starting welding or grinding work. Always ensure that there are fire extinguishers at hand when work is being carried out. Make sure that oil and fuel soaked rags, and used fuel and oil filters are stored in a safe place. Rags soaked in oil can spontaneously ignite under certain circumstances. Used fuel and oil filters are polluting waste and must be handed to an approved waste manage- ment 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. Never smoke close to the batteries. The batteries generate hydrogen gas when charged, which forms an explosive gas when mixed with air. This gas is easily ignit- ed and highly volatile. A spark, which can be caused by incorrect battery connection, can cause a single spark which is sufficient to cause an explosion with resulting damage. Do not move the connections when you attempt to start the engine (risk of sparking), and do not stand and lean over one of the batteries. Always ensure that the Plus (positive) and Mi- nus (negative) battery cables are correctly in- stalled on the corresponding terminal posts on the batteries. Incorrect installation can result in serious damage to the electrical equipment. Refer to the wiring diagram. Always use protective goggles when charging and handling the batteries. Battery electrolyte contains sulfuric acid which is highly corrosive. Should the battery electrolyte come into contact with unprotected skin wash off immediately using plenty of water and soap. If you get battery acid in your eyes, flush at once with a generous amount of water, and get medical assistance at once. Turn the engine off and turn off the power at the main switch(es) before carrying out work on the electrical system. Clutch adjustments must be carried out with the engine stopped. The existing lugs on the engine/reversing gear should be used for lifting the assembly. Always check that the lifting devises are in good condition and that they have the correct capaci- ty for the lift (the weight of the engine plus the reversing gear and extra equipment).

Safety information Group 30: Electrical system 6 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 should be parallel to each other and should be as square as possible to the top of the engine. If other equipment connected to the engine has altered its center 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 liftingdevise. Never work alone when removing heavy engine components, even when using lifting devices such as locking tackle lifts. When using a lifting device two people are usually required to do the work, one to take care of the lifting device and another to ensure that components are lifted clear and not damaged during the lifting operations. When you work aboard a boat, always make sure that there is enough space for disassembly where you are working, with no risk of personal injury or material damage. 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 run in areas where there are explosive materials. WARNING! Fuel delivery pipes must not be bent or straightened under any circumstances. Dam- aged pipes must be replaced. Never use a high-pressure washer to clean the engine. When cleaning other parts with a high- pressure washer, never direct the jet at seals, rubber hoses or electrical components. Only use the fuels recommended by Volvo Pen- ta. Refer to the Operator’s Manual. Use of fuels that are of a lower quality can damage the engine. Poor fuel can also lead to higher- maintenance costs.

7 General information About this Workshop Manual This workshop manual contains technical data, descriptions and repair instructions for the following marine diesel engines: D6-310D-B and D6-370D-B. The workshop manual can illustrate tasks done on any of the engines noted above. This means that the illustrations and photographs which clarify certain de- tails might not correspond with other engines in some cases. Repair methods are similar in all important re- spects, however. If this is not the case, this is noted. Important differences are noted separately. The engine designation and number are noted on the number plate and engine decal. The engine designation and number must always be given in all corre- spondence about any product. The Workshop Manual is produced primarily for the use of Volvo Penta workshops and service techni- cians. This assumes that people who use the Manual have basic knowledge of marine drive systems 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 sub- ject to various national safety requirements, such as U.S. Coast Guard Safety Regulations. Volvo Penta Original Spare Parts meet these specifications. Any damage, occasioned by use of non-original Volvo Penta spares for the product, will be not be compensated by the warranty offered by Volvo Penta. Certified engines When doing service and repair on emission certified engines, it is important to be aware of the following: Certification means that an engine type has been checked and approved by the relevant authority. The engine manufacturer guarantees that all engines made of the same type are equivalent to the certified engine. This makes special demands on service and repair work, as follows: ● Maintenance and service intervals recommended by Volvo Penta mustbe complied with. ● Only Volvo Penta original spares may be used. ● Service to injection pumps, pump settings and injectors must always be done by an authorized Volvo Penta workshop. ● The engine must not be converted or modified, except for the accessories and service kits which Volvo Penta has approved for the engine. ● No installation changes to the exhaust pipe and engine air inlet ducts may be done. ● No seals may be broken by unauthorized personnel. The general advice in the instruction book about operation, care and maintenance applies. IMPORTANT! Delayed or inferior care/maintenance, and the use of non-original spares parts means that Volvo Penta can no longer be re- sponsible for guaranteeing that the engine com- plies with the certified version. Damage andd /or costs which arise from this will not be compensated by Volvo Penta.

8 Repair instructions The working methods described in the Workshop Manual apply to work carried out in a workshop. For this reason, the engine is lifted out of the boat and mounted on an equipment 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. The warning signs which occur in the workshop manual (please refer to “Safety information” for their meanings). 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. All operations described in the Workshop Manual for which there are Volvo Penta Special Tools available assume that these tools are used when carrying out the repair. Volvo Penta Special Tools have been de- veloped to ensure the most safe and rational working methods possible. It is therefore the responsibility of anyone using other tools or other working methods than we recommend to determine that there is no risk of personal injury or mechanical damage or malfunction as a result. In some cases special safety precautions and user instructions may be required in order to use 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. By following these basic recommendations and using- using common sense it is possible to avoid most of the risks involved in the work. A clean work place and a clean engine will eliminate many risks of personal injury and engine malfunction. Above all, when work on fuel systems, lubrication systems, induction 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. Our common responsibility Each engine consists of a large number of collaborat- ing systems and components. Any deviation of a component from its technical specification can dra- matically increase the environmental impact of an otherwise good engine. For this reason, it is important that the specified wear tolerances are observed, that systems which are adjustable are correctly adjusted and that Volvo Penta Original Spares are used for the engine. The stated service intervals in the Mainte- nance Schedule must be observed. Some systems, such as the components in the fuel system, require special expertise and special testing equipment for service and maintenance. For environmental reasons etc., some components are sealed at the factory. It is only permissible to work on sealed components if you are authorized to do such work. Remember that most chemical products, incorrectly used, damage the environment. Volvo Penta recom- mends the use of biodegradable degreasers whenever engine components are de-greased, unless otherwise specified in the workshop manual. When working aboard a boat, be careful to ensure that oils, wash residue etc. are processed for destruction, and are not inadvertently discharged with bilge water into the environment. Tightening torques The tightening torque for vital fasteners, which should be tightened with a torque wrench, are listed in “Techni- cal Data: Special tightening torques” and noted in the job descriptions in the book. All torque specifications apply to clean screws, screw heads and mating faces. Torque data stated apply to lightly oiled or dry threads. Iflubricants, locking fluids or sealants are needed on a fastener, the type of preparation to be used will be noted in the job description. For fasteners where specific torque values are not given, please refer to “Technical data: General tightening torques”. General torque specifications are target values and the fastener does not need to be tightened with a torque wrench. Dimension Torque Nm M5 ......................................................... 6 M6 ....................................................... 10 M8 ....................................................... 25 M10 ..................................................... 50 M12 ..................................................... 80 M14 ................................................... 140 M16 ................................................... 220

Volvo Penta D6 Group 30 Electrical system Workshop and Repair Manual [en]

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