Workshop manual

EDC Fuel system

TWD740VE, TWD1231VE
 Workshop manual

EDC Fuel system

TWD740VE, TWD1231VE

Contents

Safety information .................................................... 2 Function check with diagnosis program ........... 31

General information ................................................. 5 Function check with diagnosis instrument ....... 32

General information ............................................. 32
Repair instructions .................................................. 6 Diagnosis instrument .......................................... 32
Connection .......................................................... 32
Special tools ........................................................... 10 Instrument menu functions ................................ 33
Menu operation on the instrument ..................... 33
Tightening torque .................................................. 10
Function check with diagnosis button ............... 38
Specifications ......................................................... 11 General information ............................................. 38
Reading fault codes ............................................ 38
Design and function .............................................. 13 Erasing fault codes ............................................. 38

Component description ........................................ 15 EDC fault codes ...................................................... 39

EDC Fuel system ............................................... 15
Control unit .......................................................... 17 Electric fault tracing in EDC systems ................. 42
IInjection pump, actuator, relay ......................... 20 Measurement of components in
Sensor, coolant, charge air temperature, the injection pump .............................................. 42
fuel temperature and charge pressure ............... 21
Measurement of charge
Diagnostic button, test connection .................... 22
air temperature sensor ....................................... 43
Signals to engine ................................................... 23 Measurement of coolant
Curves: Pre-heating and post-heating ............... 23 temperature sensor ............................................. 44
Input signals ........................................................ 23
Wiring diagrams ..................................................... 46
Calibration of accelerator linkage ....................... 25 Wiring diagram for TWD740VE engine .............. 46
Idling adjustment ................................................ 26 Wiring diagram for TWD1231VE engine ............ 48
Wiring diagram for control panel ........................ 50
Operation of engines with the EDC system ....... 27

Repair instructions ................................................ 28

General advice on working with EDC ................ 28
Changing the control unit ................................... 28
Venting the fuel system ..................................... 30

1
 Safety information
Introduction
The workshop manual contains technical data, descrip- Be careful with hot surfaces (exhaust pipes, tur-
tions and repair instructions for specified products or bos, charge air pipes, starting heaters etc.) and
product versions supplied by Volvo Penta. Make sure hot fluids in pipes and hoses on an engine which
you use the correct workshop literature. is running or which has just stopped. Re-install all
Read the available safety information, “General in- guards which have been removed during service
formation“ and “Repair instructions“ before you work, before re-starting the engine.
start to do any service work.
Make sure that the warning or information labels
on the product are always clearly visible.Replace
Important labels which have been damaged or painted over.

The following special warning signs are found in the Never start an engine without the air filter in pla-
workshop manual and on the product. ce. The rotating compressor turbine in the turbo-
WARNING! Warns for the risk of personal injury, charger can cause severe injury. Foreign bodies
major damage to product or property, or serious in the inlet pipe can also cause severe mechani-
malfunctions if the instruction is ignored. cal damage.

IMPORTANT! Is used to call attention to things Never use start spray or similar products as a
which could cause damage or malfunctions to starting aid. Explosions could occur in the inlet
product or property. manifold. Danger of personal injury.

NOTE! Is used to call attention to important informa- Only start the engine in a well-ventilated area.
tion, to facilitate work processes or operation. When operated in a confined space, exhaust fu-
mes and crankcase gases must be ventilated
To give you a perspective on the risks which always from the engine bay or workshop area.
need to be observed and precautions which always
have to be taken, we have noted them below. Avoid opening the coolant filling cap when the en-
gine is hot. Steam or hot coolant can spray out at
the same time as the pressure which has built up
Make it impossible to start the engine by cutting is lost. Open the filler cap carefully if necessary,
system current with the main switch(es) and lock and release the excess pressure in the cooling
it (them) in the off position before starting service system. Be extremely careful if a tap, plug or
work. Fix a warning sign by the helmsman’s seat. coolant hose has to be removed from a hot engi-
ne. Steam or hot coolant can stream out in an
All service work should normally be done on a unexpected direction.
stationary engine. Some work, such as adjust-
ments, need the engine to be running, however. Hot oil can cause burns. Avoid skin contact with
Going close to a running engine is a safety risk. hot oil. Make sure that the oil system is de-pres-
Remember that loose clothes, long hair etc. can surised before doing any work on it. Never start
catch on rotating components and cause severe or run the engine with the oil filler cap removed,
injury. because of the risk of oil spillage.
If work is done adjacent to a running engine, a
careless movement or a dropped tool can lead to Stop the engine before doing any work on the
personal injury in the worst case. cooling system.

2
 General instructions

Always use goggles when doing any work where Make sure that oil and fuel soaked rags, and
there is any risk of splinters, grinding sparks, used fuel and oil filters are stored in a safe place.
acid splash or other chemicals. Your eyes are Oil soaked rags can self-ignite in the right cir-
extremely sensitive. Injury can cause blindness! cumstances. Used fuel and oil filters are polluting
waste and must be handed to an approved waste
Avoid skin contact with oil! Long-term or repeated management facility for destruction, together with
skin contact with oil can make your skin dry out. used lubrication oil, contaminated fuel, paint resi-
The consequence is irritation, dry skin, eczema due, solvents, degreasers and wash residue.
and other skin disorders. Used oil is more haz-
ardous to health than new oil. Use protective glo-
ves and avoid oil-soaked clothes and rags. Wash Batteries must never be exposed to open flames
regularly, especially before meals. Use special or electric sparks. Do not smoke close to the bat-
skin cream to avoid drying and facilitate skin cle- teries. The batteries generate hydrogen gas when
aning. charged, which forms an explosive gas when
mixed with air. This gas is very flammable and
Most chemicals intended for the product (e.g. highly explosive. A spark, which can be formed if
engine and transmission oils, glycol, petrol (gaso- the batteries are wrongly connected, is enough to
line) and diesel oil) or chemicals for workshop make a battery explode and cause damage. Do
use (e.g. degreasers, paints and solvents) are not move the connections when you attempt to
hazardous. Read the instruction on the packages start the engine (risk of arcing), and do not stand
carefully! Always observe the safety advice (e.g. and lean over one of the batteries.
use of breathing protection, goggles, gloves etc.).
Make sure that other personnel are not inadver-
tently exposed to hazardous substances, such Never mix up the battery positive and negative
as via the air they breathe. Ensure good ventila- poles when the batteries are installed. If the bat-
tion. Handle used and surplus chemicals in the teries are wrongly connected, this can cause se-
prescribed manner. vere damage to the electrical equipment. Please
check the wiring diagram!

Be very careful when searching for leaks in the

fuel system and testing fuel injectors. Use gogg- Always use goggles when charging and handling
les. The jet from a fuel injector is under very high batteries. Battery electrolyte contains highly cor-
pressure, and has considerable penetration abili- rosive sulphuric acid. If this comes into contact
ty; fuel can force its way deep into body tissues with your skin, wash at once with soap and a lot
and cause serious damage. Risk of blood poiso- of water. If you get battery acid in your eyes,
ning (septicaemia). flush at once with a lot of water, and get medical
assistance at once.
WARNING! Fuel delivery pipes must not be
bent or straightened under any circumstances. Stop the engine and cut the system current with
Damaged pipes must be replaced. the main switch(es) before doing any work on the
electrical system.
All fuels, and many chemicals, are flammable.
Make sure that open flames or sparks can not The clutch must be adjusted with the engine shut
set them alight. Petrol (gasoline), some thinners off.
and hydrogen gas from batteries are extremely
flammable and explosive when mixed with air in
the correct ratio. Do not smoke! Provide good The existing lugs on the engine should be used
ventilation and take the necessary precautions for lifting. Always check that the lifting devices
before you start welding or grinding in the vicinity. are in good condition and that they have the cor-
Always have a fire extinguisher easily available rect capacity for the lift (the weight of the engine
near the workplace. plus the gearbox and extra equipment if instal-
led). The engine should be lifted with a customi-
sed 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.

3
General instructions

If other equipment connected to the engine has Only use the fuels recommended by Volvo Pen-
altered its centre of gravity, special lifting devic- ta. Please refer to the instruction book. The use
es may be needed to obtain the correct balance of fuel of inferior quality can damage the engine.
and safe handling. In a diesel engine, poor fuel can cause the regu-
lation rod to bind and the engine will over-rev, en-
Never do any work on an engine which just
tailing a strong risk of personal injury and ma-
hangs from a lifting device.
chinery damage. Poor fuel can also lead to high-
er maintenance costs.

Never work alone when heavy components are Remember the following when washing with a
to be dismantled, even when safe lifting devices high pressure washer: Never aim the water jet at
such as lockable blocks & tackle are used. seals, rubber hoses, electrical components or the
Even when lifting devices are used, two people radiator. Never use the high pressure water for
are needed in most cases. One who operates engine cleaning.
the lifting device 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 minimise the risks of explosion
and fire. The engine must not be operated in en-
vironments with adjacent explosive media.

© 2000 AB VOLVO PENTA

We reserve the right to make modifications
without prior notice.
Printed on environmentally compatible paper.

4
 General information

About the workshop manual Certified engines

This workshop manual contains descriptions and repair When service or repairs are done to an emission
instructions for the standard versions of the certified engine, which is used in an area where ex-
TWD740VE and TWD1231VE engines. haust emissions are regulated by law, it is impor-
tant to be aware of the following:
The engine designation and number are always given
on the type plate (please refer to page 9). The engine Certification means that an engine type has been
designation and number must always be given in all checked and approved by the relevant authority. The
correspondence about an engine. engine manufacturer guarantees that all engines made
of the same type are equivalent to the certified engine.
The workshop manual has been primarily prepared for
Volvo Penta service workshops and their qualified per- This put special demands on service and repair
sonnel. This assumes that people who use the manual work, as follows:
have basic skills and can do the tasks of a mechanical
or electrical nature associated with the trade. • Maintenance and service intervals recommended
Volvo Penta constantly improves its products, so we by Volvo Penta must be complied with.
reserve the right to make modifications without prior
notification. All information in this manual is based on • Only Volvo Penta original spares may be used.
product data which was available up to the date on • Service to injection pumps, pump settings and in-
which the manual was printed. Any material changes jectors must always be done by an authorised Vol-
introduced into the product or service methods after vo Penta workshop.
this date are notified by means of Service Bulletins.
• The engine must not be converted or modified, ex-
cept for the accessories and service kits which Vol-
Spare parts vo Penta has approved for the engine.

Spare parts for electrical and fuel systems are subject • Installation changes to the exhaust pipe and engine
to various national safety requirements. Volvo Penta air inlet ducts must not be done.
Original Spares comply with these requirements. No
damage whatever, occasioned by use of non-original • No seals may be broken by unauthorised person-
Volvo Penta spares for the product, will be compensa- nel.
ted by the warranty offered by Volvo Penta. The general advice in the instruction book about opera-
tion, care and maintenance apply.

IMPORTANT! Delayed or inferior care/mainte-

nance, and the use of non-original spares, mean
that AB Volvo Penta can no longer be responsi-
ble for guaranteeing that the engine complies
with the certified version.
Damage, injury and/or costs which arise from
this will not be compensated by Volvo Penta.

5
 Repair instructions
The work methods described in the workshop manual
apply to work in a workshop environment. For this rea-
Our common responsibility
son, the engine is lifted out and mounted on an engine Each engine consists of a large number of collabora-
support. Renovation work which does not need the eng- ting systems and components. Any deviation of a com-
ine to be lifted out can be done in situ, with the same ponent from its technical specification can dramatically
work methods, unless otherwise specified. increase the environmental impact of an otherwise
The warning signs which occur in the workshop manual good engine. For this reason, it is extremely important
(please refer to “Safety information“ for their meanings) that specified wear tolerances are maintained, that sys-
tems with adjustment facilities are correctly adjusted
WARNING! and that Volvo Penta Original Spares are used for the
engine. The times noted in the engine maintenance
schedule must be observed.
IMPORTANT!
Some systems, such as components in the fuel sys-
NOTE! tem, may require special competence and special test
equipment. For environmental reasons etc., some com-
are not comprehensive in any way, since we can not of
ponents are sealed at the factory. It is only permissible
course foresee everything, since service work is done
to work on sealed components if you are authorised to
in highly varying circumstances. For this reason, all we
do such work.
can do is to point out the risks which we believe could
occur due to incorrect work in a well-equipped work- Remember that most chemical products, incorrectly
shop, using work methods and tools tested by us. used, damage the environment. Volvo Penta recom-
mends the use of biodegradable degreasers whenever
In the workshop manual, all tasks for which there are
engine components are de-greased, unless otherwise
Volvo Penta special tools, are done using these tools.
specified in the workshop manual. Be careful to ensure
Special tools are specially prepared to permit the sa-
that oils, wash residue letc. are processed for destruc-
fest and most rational work methods possible. For this
tion, and are not inadvertently discharged to the envi-
reason, it is the responsibility of the person who uses
ronment.
other tools or other work methods than those recom-
mended by us, to ensure that there is no risk of perso- Tightening torque
nal injury or material damage, and that they can not
cause any malfunctions. The tightening torque for vital fasteners, which should
be tightened with a torque wrench, are listed in “Techni-
In some cases, special safety regulations and user ins-
cal Data“. “Tightening torque“ and are specified in the
tructions are available for the tools and chemicals
workshop manual job descriptions. All torque specifica-
mentioned in the workshop manual. These rules must
tions apply to clean screws, screw heads and mating
always be observed, so there are no special instruc-
faces. The torque specifications apply to lightly oiled or
tions about this in the workshop manual.
clean screws. If lubricants, locking fluids or sealants
The majority of risks can be prevented by taking cer- are needed on a fastener, the type of preparation to be
tain elementary precautions and using common sense. used will be noted in the job description and in “Tight-
A clean workplace and a clean engine eliminate many ening Torques“. Where a particular torque value is not
risks of both personal injury and malfunction. specified for any fastener, the general tightening tor-
Above all, when work on fuel systems, lubrication sys- ques in the table below shall apply. The torque specifi-
tems, inlet systems, turbocharger, bearing caps and cation is a target value and the fastener does not need
seals is done, it is extremely important that no dirt or to be tightened with a torque wrench.
other kinds of foreign particles are able to get in, since
this would otherwise cause malfunctions or shortened Dimension Tightening torque
repair life.
Nm
M5 ......................................................... 6
M6 ......................................................... 10
M8 ......................................................... 25
M10 ....................................................... 50
M12 ....................................................... 80
M14 ....................................................... 140

6
 General instructions

It is therefore important that the correct types of sea-

Torque/angle tightening lant and locking fluids are used on the fasteners where
In torque/angle tightening, the fastener is tightened to needed, to give a fully acceptable service result.
the specified torque, and tightening then continues th- In the workshop manual, the relevant chapters contain
rough a pre-determined angle. Example: for 90° angle notes on the preparations used in our engine produc-
tightening, the fastener is turned a further 1/4 turn in tion.
one sequence, after the specified tightening torque has
In service work, the same preparations or preparations
been achieved.
of corresponding properties, but of other makes, shall
be used.
Lock nuts When sealants and locking fluids are used, it is impor-
tant that the surfaces are free from oil, grease, paint
Dismantled locknuts shall not be re-used, they shall be and rust-protection, and that they are dry.
replaced by new ones, since the locking properties are
Always observe the manufacturer’s instructions about
impaired or lost when the nut is used several times. On
temperatures of use, hardening times and other instruc-
locknuts with plastic inserts, such as Nylock®, the
tions for use of the product.
tightening torque specified in the table must be reduced
if the Nylock® nut has the same nut height as a stan- Two basic types of preparation are used on the engine,
dard fully metallic hexagonal nut. Reduce the tightening characteristics are as follows:
torque by 25% if the screw dimension is 8 mm or grea- RTV preparations (Room Temperature Vulcanizing).
ter. On Nylock ® nuts with higher nut height, where the These are mostly used together with gaskets, such as
fully metallic thread is as high as on a standard hexa- sealing gasket joints, or are brushed on gaskets. RTV
gonal nut, use the tightening torques in the table. preparations are fully visible when the component has
been disassembled; old RTV compound must be remo-
ved before the joint is sealed again.
Strength classes The following RTV preparations may be mentioned in
Screws and nuts are sub-divided into different strength the workshop manual: Loctite ® 574, Permatex ® No.
classes. Classification is indicated by markings on the 3, Permatex ® No 77. Remove old sealant with denatu-
screw head. Markings of a higher number indicate red alcohol in each case.
stronger material. For example, a screw marked 10-9 is Anaerobic preparations. These preparations harden in
stronger than one marked 8-8. For this reason, it is im- the absence of air. These preparations are used when
portant when fasteners are dismantled, that the screws two solid components, such as two cast components,
are put back in the correct places when they are re-in- are fitted together without a gasket. Common uses are
stalled. When you change screws, please check the also to lock and seal plugs, stud threads, taps, oil
spare parts catalogue to ensure that the correct ver- pressure monitors etc. Hardened anaerobic prepara-
sions are obtained. tions are glassy and for this reason, the preparations
are coloured to make them visible. Hardened anaerobic
preparations are highly resistant to degreasers, and old
Sealants compound can not be removed. On re-installation, de-
grease carefully and then apply new sealant.
Several different types of sealant and locking fluids are
The following anaerobic preparations may be mentio-
used on the engine. The properties of the preparations
ned in the workshop manual: Loctite ® 572 (white),
differ, and they are intended for different strengths of
Loctite ® 241 (blue).
fastener, temperature, resistance to oil and other che-
micals, and for the different materials and gap thick-
nesses found in the engine. NOTE! Loctite® is a registered trademark belonging to the Loctite
Corporation, Permatex® is a registered trademark belonging to the
Permatex Corporation.

7
General instructions

Safety rules for

Fluorocarbon rubber
Fluorocarbon rubbers are commonly used materials in
seal rings on shafts, O-rings etc.
When flourocarbon rubber compounds are exposed to
high temperatures (above 300° C), hydrofluoric acid
can be formed, which is highly corrosive. Skin contact
can cause severe chemical burns. If it splashes in
your eyes, this can cause severe chemical burns. If
you breathe the fumes, you can suffer lung and bron-
chial injury.

WARNING! Be very careful when working on en-

gines which have been exposed to high tempera-
tures, such as overheating caused by a seizure
or fire. Seals must never be cut with a flame
torch during disassembly, or burned in uncon-
trolled circumstances afterwards.
• Always use chloroprene rubber gloves (gloves for
chemicals handling) and goggles.
• Handle the removed seal in the same way as corro-
sive acid. All residues, including ash, can be
strongly corrosive. Never use compressed air to
blow components clean.
• Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under run-
ning water before you take them off.
The following seals are most probably made from fluo-
rocarbon rubber:
Seal rings for crankshafts, camshafts, countershafts.
O-rings, irrespective of where they are installed. O-
rings for cylinder liner sealing are almost always made
of fluorocarbon rubber.
Please note that seals which have not been expo-
sed to high temperature can be handled normally.

8
 General instructions

Location of engine signs

The engines are supplied with two engine signs, of
which one is installed on the engine block, as in the il-
lustration.
The other sign is supplied loose, for installation in a su-
itable location close to the engine.

Explanation of engine designation:

E.g. TWD1231VE
T – Turbodiesel
W – Water to air, intercooler
D – Diesel engine
12 – Displacement, litre
3 – Generation
1 – Version
V – Stationary and mobile operation
E – Emission control

1. Engine designation
2. Product number
3. Serial number
4. Engine power, net, (without fan)
5. Engine power, net, (with fan)
6. Max. engine speed
7. Piston position/Injection advance (BTDC)

9
 Special tools

Diagnosis tool* with cable 885 2931 Tool for removing fuel and oil filter 999 91796.

* Order the cartridge separately, part number 885312

Data cable* for diagnostic program 885337 Multimeter 951 00608

* When you order the data cable, an order form is enclosed

for software.

Tightening torque
Coolant temperature sensor ................................................................................................................ max. 30 Nm
Charge air temperature sensor ............................................................................................................ max. 30 Nm
Control unit gland in fuel fine filter bracket .............................................................................................. 38 ± 6 Nm

10
 Specifications
Technical data
The figures in brackets are also found in the “Wiring di-
agrams“ chapter at the back of this manual and in the
“Component description“ chapter.

Control unit, (16)

Voltage ........................................................... 9 – 32 V
Connector ...................................................... 42-poligt

Components in injector pump

actuator, (17, 18, 19)
Position sensor ...................................... inductive type
Speed sensor ......................................... inductive type
Control solenoid ..................................... inductive type

Relays, (5, 6, 7)
Type ..................................... Switching, 24 V, 10/20 A

TWD740VE TWD1231VE

Connector (14)
Connector .............................................. 2 pcs. 16 pin
(please refer to the label on the inside of the junction
box)

11
Specifications

Test connector, diagnosis (15)

Connector ........................................................... 2 pin
Located in junction box, centrally on one side of the en-
gine.

TWD740VE TWD1231VE

Fuse (13)
Circuit breaker ........................................................ 8 A

TWD740VE TWD1231VE

Coolant temperature sensor (12)

Type: Thermistor with negative temperature coefficient,
so-called NTC resistor.
Measurement range ........................ –30° C to +120° C

Charge air temperature sensor (21)

Type: Thermistor with negative temperature coefficient,
so-called NTC resistor.
Measurement range ......................... -40° C to +150° C

12
 Design and function

General information
EDC (Electronic Diesel Control) is a system in which Difference between mechanical and electronic
the amount of fuel injected is controlled electronically, regulator
as distinct from the systems where the injected fuel
volume is mechanically controlled. In an injection pump with a centrifugal regulator, the in-
jection volume is controlled mechanically. The centrifu-
The main components of an EDC system are a micro- gal regulator is influenced by accelerator position, and
processor based control unit, and electromagnetic ac- compares it with the injector pump speed. The amount
tuator and a number of sensors which continually pro- of fuel injected is increased or reduced, to make the in-
vide the control unit with information. jection pump turn at the speed corresponding to the ac-
The EDC system celerator position.

The injection pump on the TWD740VE and In the EDC system, the centrifugal regulator in the in-
TWD1231VE engines has an electromagnetic actuator. jection pump is replaced by an electromagnetic actua-
The actuator contains a solenoid which acts on the in- tor. The actuator is controlled by the control unit, which
jection pump control rod, and thus influences the takes its information from a number of sensors located
amount of fuel injected. on the engine and controls, in its turn.

The EDC system has a built-in smoke limiting function. Injection pumps with a centrifugal regulator are
The system measures charge air pressure and mani- equipped with a smoke limiter, in the form of a pres-
fold temperature, and thus calculates the amount of air sure-dependent full load stop.
available. The amount of air available determines the Engines with the EDC system do not have a mechani-
maximum permissible amount of fuel injected, in its cal smoke limiter. The corresponding function is inte-
turn. grated in the EDC system instead.
In order to achieve the minimum amount of emissions,
the system measures the coolant temperature and
uses this to determine the amount of preheating and
post heating in the engine (please refer to the “Compo-
nent description“ chapter). Curves, Preheating and Post
Heating, and correct fuel volume. The system also de-
cides the maximum amount of fuel which can be inject-
ed at each engine speed.

13
Design and function

Engine speed Coolant temperature

Accelerator linkage Charge air temperature

Control rod position Charge air pressure

Regulator selector Fuel temperature

EDC system control unit Monitoring functions

The control unit, which is built into the fuel filters, re- The EDC system contains functions for monitoring the
ceives signals from the following sensors (sensor loca- following parameters on the engine:
tion is noted in brackets).
• Control rod position (injection pump)
• Control rod position
• Engine speed (injection pump)
• Engine speed
• Charge air pressure (control unit)
• Charge air pressure
• Charge air temperature (inlet manifold)
• Charge air temperature
• Coolant temperature (thermostat housing)
• Coolant temperature
• Fuel temperature (control unit)
• Fuel temperature
• Accelerator position (driver’s foot pedal)
• Excess current, (control unit)
Using these signals, the control unit directs the injec-
tion pump to provide the engine with the correct
amount of fuel under every loading. If anything abnormal occurs, the control unit generates
and stores a code. The diagnosis lamp on the EDC
if the above-mentioned sensors give unreasonable val-
control panel then begins to flash.
ues, the system takes various measures to protect the
engine and its auxiliaries (e.g. the turbocharger). The number of flashes given by the diagnosis lamp
corresponds to the relevant fault code, which is ob-
To protect the engine if there is excessive charge tem-
tained by pressing the diagnosis button.
perature, coolant temperature, charge air pressure, en-
gine speed, the EDC system reduces the amount of Please refer to the “Function checking with diagnosis
fuel injected (and thus reduces power) until the relevant button“ chapter for function checking with the diagnosis
values return to the permissible interval. The engine button, and fault codes.
must be re-started to get normal power back.
In addition, there are Limp-home values (emergency
control parameters) stored in the control unit. These
come into action if there are any technical faults in the
system or its auxiliaries, sensors etc. Limp-home val-
ues are activated to allow the engine to continue in op-
eration, but at reduced performance.
The control unit also contains a diagnosis function,
which can help the user/service personnel to quickly
find any faults in the system, by using a diagnosis
lamp, diagnosis instrument or PC based diagnosis pro-
gram.

14
 Component description

TWD740VE

Component list* (Only EDC system)

1. – 14. 2 pcs. 16 pin connectors
2. Starter motor 15. Test connector
3. Alternator 16. Control unit
4. Pre-heating relay 17. Control solenoid (located inside actuator)
5. Starter relay 18. Engine speed sensor (located inside actuator)
6. Main relay 19. Control rod position sensor (located inside actuator)
7. Stop relay 20. Coolant temperature sensor (EDC)
8. – 21. Charge air temperature sensor
9. – 22. –
10. – 23. –
11. – 24. Fuel temperature sensor, located in control unit
12. – 25. Charge air temperature sensor, located in control unit
13. Circuit breaker

* The positions in the illustration of the EDC system are the same
as the positions in the wiring diagram and show where on the
engine each component is located.

15
Component description

TWD1231VE

Component list* (Only EDC system)

1. – 14. 2 pcs. 16 pin connectors
2. Starter motor 15. Test connector
3. Alternator 16. Control unit
4. Pre-heating relay 17. Control solenoid (located inside actuator)
5. Starter relay 18. Engine speed sensor (located inside actuator)
6. Main relay 19. Control rod position sensor (located inside actuator)
7. Stop relay 20. Coolant temperature sensor (EDC)
8. – 21. Charge air temperature sensor
9. Switch for sensor, coolant level 22. –
10 . – 23. –
11. – 24. Fuel temperature sensor, located in control unit
12. – 25. Charge air temperature sensor, located in control unit
13. Circuit breaker

* The positions in the illustration of the EDC system are the

same as the positions in the wiring diagram and show where
on the engine each component is located.

16
 Component description

Control unit
Control unit, (16)
The control unit is located by the fuel filter.
There is a 42 pin sealed connector at the rear of the
control unit for connecting the cable harness. The con-
trol unit cables are protected by flexible plastic hoses.
A hose connection for measuring the charge pressure
is located underneath the control unit.
The control unit, which is the central section of the
EDC system, receives continual information from sen-
sors located on the engine and controls. The informa-
tion is processed by the control unit, which sends sig-
nals to the electromagnetic acutator. The actuator then
controls the amount of fuel supplied under each load-
ing. EDC system control unit
The control unit also has the task of monitoring the
system and generating fault codes when any faults oc-
cur.

Limits for the TWD740VE

Alarm values
Highest permissible values of charge air temperature,
coolant temperature etc. If the alarm values are ex-
ceeded, the system reduces the fuel value until the
value falls within the permissible value again. The en-
gine must be re-started to get normal power back.
The following alarm limits are pre-programmed into the
control unit:
Highest permissible charge
air temperature ............................................120° C
Highest permissible fuel temperature ........... 85° C
Highest permissible coolant temperature
on/off: ..................................................... 101/98° C
Highest permissible engine speed:
175 kW ..................................................... 2800 rpm
203 kW ..................................................... 2600 rpm
Highest permissible frequency .................. 1875 Hz
Lowest permissible frequency ...................... 30 Hz
Highest permissible charge pressure, please refer to
the Max curve in the diagram. Diagram for charge pressure, TWD740VE
NOTE! Pressure is measured as absolute pressure.

17
Component description

Limp home values (emergency control values)

The basic values are used by the control unit to allow
the engine to keep going if there is a technical fault in
the system or its auxiliary equipment, sensors etc.
The following values (Limp home values) are stored in
the control unit:
Charge air temperature ................................. 55° C
Fuel temperature .......................................... 40° C
Coolant temperature ..................................... 10° C
Charge air pressure .................. Please refer to the
diagram on the
previous page
Engine speed .......................................... 1000 rpm

Extreme values
Highest and lowest values, and the time that an ex-
treme value has been exceeded are stored in the con-
trol unit. These values can be read by means of a diag-
nosis program (please refer to the “Function check with
diagnostic program“ chapter)
The following extreme values are pre-programmed into
the control unit:
Charge air temperature ................................ 110° C
Low charge air temperature ............................ 0° C
High fuel temperature .................................... 60° C
Low fuel temperature ...................................... 0° C
High coolant temperature .............................. 95° C
Low coolant temperature ................................ 5° C
High charge pressure:
175 kW ..................................................... 310 kPa
203 kW ..................................................... 325 kPa
High engine speed:
175 kW ................................................... 2530 rpm
203 kW ................................................... 2320 rpm

18
 Component description

Limits for the TWD1231VE

Alarm values
Highest permissible values of charge air temperature,
coolant temperature etc. If the alarm values are ex-
ceeded, the system reduces the fuel value until the
value falls within the permissible value again. The en-
gine must be re-started to get normal power back.
The following alarm limits are pre-programmed into the
control unit:
kPa
Highest permissible charge air 400
temperature* ............................................... 150° C 375
Highest permissible fuel temperature ........... 85° C 350
325
Highest permissible coolant temperature
on/off ...................................................... 103/96° C 300
275
Highest permissible engine speed ............ 2500 rpm
250
Highest permissible charge pressure, please refer to 225
the Max curve in the diagram.
200
* Agri Boost; 120° C
175

150
Limp home values (emergency control values) 125
The basic values are used by the control unit to allow
100
the engine to be driven if there is a technical fault in
900 1100 1300 1500 1700 1900 r/min
the system or its auxiliary equipment, sensors etc.
310 kW 294 kW 256 kW
The following values (Limp home values) are stored in 308 kW 275 kW Limp home
the control unit:
Charge air temperature ................................. 55° C Diagram for charge pressure, TWD1231VE
NOTE! Pressure is measured as absolute pressure.
Fuel temperature .......................................... 40° C
Coolant temperature ..................................... 10° C
Charge air pressure .... Please refer to the diagram
Engine speed .......................................... 1000 rpm

Extreme values
Highest and lowest values, and the time that an ex-
treme value has been exceeded are stored in the con-
trol unit. These values can be read by means of a diag-
nosis program (please refer to the “Function check with
diagnostic program“ chapter)
The following extreme values are pre-programmed into
the control unit:
Charge air temperature .................................. 110° C
Low charge air temperature ............................... 0° C
High fuel temperature* ..................................... 55° C
Low fuel temperature .........................................0° C
Engine power (kW) 256 275 294 308 310
High coolant temperature ................................ 95° C
Low coolant temperature ...................................5° C High charge air
pressure** (kPa) 295 295 320 325 325
High charge air pressure .... Please refer to the table
High engine speed (rpm) 2100 2000* 2000 1900 2000*
High engine speed ............ Please refer to the table

* Agri Boost; 275/310; 2200 rpm

* Agri Boost; 60° C ** Absolute pressure

19
Component description

Injection pump, actuator, relay

Injection pump
The injection pump is a piston-type unit, located on the
left of the engine. It is driven from the timing gear.
TWD740VE and TWD1231VE have an electromagnetic
actuator controlled by the control unit.
The engines do not have mechanical smoke limiters.
The corresponding function is integrated in the EDC
system instead.

Location of injection pump, TWD740VE

Location of injection pump, TWD1231VE

Actuator, (17, 18, 19)

The acutator is electromagnetic and is controlled by
the control unit. It contains the following components:

• Control solenoid (17)

The control magnet is a solenoid, and gov-
erns the movement of the control rod.

• Engine speed sensor (18)

The engine speed sensor informs the control
unit about engine speed.

• Position sensor (19)

The position sensor informs the control unit
about control rod position. This allows the
control unit to control the movement of the
control rod, and to decide at every instant
whether to increase or reduce the control so- Electromagnetic actuator, EDC
lenoid current.

Relays, (5, 6, 7)
The three relays, starter relay (5), main relay (6), and
stop relay ( 7) are located in the junction box. This is
located on one side of the engine.
The start and stop functions are controlled by a switch-
ing relay each. The three relays are identical, and mutu-
ally interchangeable.

TWD740VE TWD1231VE

20
 Component description

Sensor, coolant, charge air, fuel temperature and charge air pressure

Coolant temperature sensor (12)

The sensor, which is located in the thermostat housing,
gives the control unit information about engine coolant
temperature. This consists of a non-linear resistor,
whose resistance is highly dependent on the tempera-
ture of the resistor body. The resistance falls as the
temperature rises.

Charge air temperature sensor (20)

The sensor is located underneath the intercooler on the
right side of the engine. This consists of a non-linear re-
sistor, whose resistance is highly dependent on the
temperature of the resistor body. The resistance falls
as the temperature rises.

Fuel temperature sensor (21)

The sensor is located inside the fixing lug on the con-
trol unit for the fine fuel filter.
The fuel flows from the filter head, via the fixing lug
and on through the filter, back into the system. When
the fuel passes the fixing lug, the sensor provides in-
formation about current fuel temperature to the control
unit. The fuel also cools the control unit to a certain ex-
tent.
The sensor consists of a non-linear resistor, whose re-
sistance is highly dependent on the temperature of the
resistor body. The resistance falls as the temperature
rises.
Since the sensor is integrated into the control unit, it
can not be replaced separately, the entire control unit
must be changed if necessary.

Charge air pressure sensor (22)

The sensor, which is integrated into the control unit,
senses the charge air pressure via an air pressure
pipe, which is connected between the inlet manifold
and the T-nipple underneath the control unit. The sensor
measures absolute pressure, which is the sum of
charge pressure plus atmospheric pressure.
Since the sensor is integrated into the control unit, it
can not be replaced separately, the entire control unit
must be changed if necessary.

21
Component description

Diagnostic button, test connection

Diagnostic button
An EDC panel, containing a diagnostic button (yellow),
is provided to monitor the EDC system functions. This
starts to flash if the EDC system receives abnormal
signals or if any technical problem occurs with the sys-
tem.
If the engine is to be installed in a vehicle, it is the re- DIAGNOSTIC BUTTON
sponsibility of the vehicle constructor to connect a diag-
nostic button in a suitable location, such as the instru-
ment panel.
NOTE! If the button is depressed when the lamp flash-
es, the lamp will flash out a two-digit fault code, please
refer to the “Function check with diagnostic button“
chapter.

Test/diagnostic connector (15)

A test/diagnostic connector is available in the junction
box. If the engine is installed in a vehicle, a diagnostic
button should be installed on the instrument panel etc.

TWD740VE TWD1231VE

Alternator (3)
An alternator with built-in zener diodes must be used to
protect the electronics. Please contact Volvo Penta
when selecting the alternator.

22
 Signals to engine
Pre-heating and post heating time
The EDC system is equipped with software to control pre-heating of the engine before starting, and subsequent
warming up of the engine after starting. Please refer to the “Operating an engine with EDC system, starting and
stopping“ chapter.

TWD740VE TWD1231VE

Input signals
There are three ways to control engine speed:

• Accelerator potentiometer: 0.4 to 2–2.5 kΩ (The potentiometer must not go below 400 Ω). Must be cali-
brated, please refer to the “Calibrating the accelerator“ chapter.

Ω
0.4 to 2 – 2.5 kΩ
100 – 300 Ω 100 – 300 Ω

400 – 700 Ω

2* 3* 4*

* According to the engine connector on the higher-level cable electrical system, please refer to the “Wiring diagrams“ chapter.

23
Signals to engine

• Voltage. Pins 3 and 4 on the connector (item 17) in the higher-level cable electrical system, please refer
to the “Wiring diagrams“ chapter

100% on the Y axis corresponds to full

throttle and 0% corresponds to idling.

Voltage control. 0.8 V corresponds to idling and 2.8 V corresponds to full throttle.

• Frequency. “PWMIN” on the engine wiring diagram, please refer to the “Wiring diagram” chapter.

100% on the Y axis corresponds to full

throttle and 0% corresponds to idling.

Frequency control. 85 Hz corresponds to idling and 350 Hz corresponds to full throttle.

Input signal appearance with frequency control

24
 Calibration of accelerator linkage

Calibration of EDC unit

The engine must be calibrated when controlled by the
accelerator potentiometer.
When calibrating, it is a good idea to install a switch
(1) between pin 2 in the “Female Connector“ in the
junction box, and the positive battery terminal, as in
the adjacent sketch. The voltage can also be taken
from the positive (+) terminal in the junction box, or
from the battery. The switch should be spring biased
and “normally open“.

Calibration
1. Set the accelerator to idling.

2. Erase any fault codes (please refer to the

“Function checking with diagnosis button“
chapter).

3. Switch off system voltage.

4. Press switch (1). Keep the switch depressed and

switch the current on. Then keep the switch de-
pressed for a further 3 seconds.

5. Release the switch. The diagnosis lamp should

now flash, as a confirmation that the EDC sys-
tem is in calibration mode.

6. Move the accelerator to full throttle position.

Keep the control in this position. Acknowledge by
pressing the switch for at least 3 seconds. DIAGNOSTIC BUTTON

7. Move the accelerator to idling position. Keep the

control in this position. Acknowledge by pressing
switch (1) for at least three seconds.

8. Finish calibrating by pressing the switch again.

The diagnosis lamp will stop flashing and calibra-
tion is completed.

25
Calibration of accelerator linkage

Idling adjustment
Idling speed is adjusted to 600 rpm when the engine is
delivered. If necessary, the idling speed can be adjust-
ed in the range from 550-1000 rpm (TWD740VE) and
550-900 rpm (TWD1231VE).
NOTE! Adjustment must be done on a warm engine.
1. Enter calibration mode as in items 1-5.

2. Start the engine. You can now adjust the idling

speed with the accelerator, within the engine
speed range as above. (This area is equal to the
working range of the control.)

3. Set the desired engine speed and press the

switch.
Idling speed is now stored in the control unit
memory.

26
 Operation of engines with the EDC system

Starting the engine

The EDC system is equipped with software for control-
ling the way the engine is warmed up before starting,
and for continued warming after starting, in accordance
with the diagram in the “Signals to engine“ chapter.
When the start button is pressed, pre-heating of the
engine starts, and then a start attempt is done for up
to 30 seconds. When the engine has started, post-
heating starts, in accordance with the diagram in the
“Signals to engine“ chapter.
To start the engine at once (i.e. without pre-heating)
press the start button twice, then keep it depressed
during the start attempt.
The amount of fuel supplied during starting is deter-
mined by the coolant temperature.
NOTE! Engines with EDC need to be cranked longer by
the start motor than equivalent engines with mechani-
cal injection. This is because the EDC system pre-
heats the combustion chambers during starting, to re-
duce exhaust emissions.

Stopping the engine

Engines with the EDC system are provided with elec-
tronic engine shut-off. To stop the engine, press the
stop button, and the current will be cut and the engine
will be stopped by the stop relay.
Do not use the main switch, since transients can be
generated by the alternator.
This could permanently damage the alternator and con-
trol unit.

27
 Repair instructions

General advice on working with EDC Changing the control unit

NOTE! The figures in the repair instructions below ap-
ply to the TWD1231VE, but the principles are the same
for the TWD740VE.
Follow the instructions below, to avoid damage to the
EDC system control unit.
• Never turn off the main switch when the en-
gine is running.
• Never undo the battery cables when the en-
gine is running.
• When the batteries are quick charged, turn
the main switch off or undo the battery ca-
bles. 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 voltag-
es and damage the control unit.
• Disconnect the main switch before undoing 1. Control unit 3. Connector
the 42 pin connector on the control unit. 2. Fuel fine filter 4. Hose connector, charge pressure
• If you discover any damage on the cable har- Control unit with connectors
nesses, undo the connector on the control
unit.

IMPORTANT! Always undo the connector on the

control unit before doing any welding. 1. Clean the filter bracket carefully.

• When a connector is undone from a sensor,

be careful to ensure that the connector pins
are not exposed to oil or other fluids. This can
cause contact problems.

2. Remove the control unit connector, by insert-

ing a screwdriver between the red catch arm
and the connector. Turn the screwdriver to
partly pull the catch arm out of the connector.

28
 Repair instructions

3. Pull the catch arm down at the same time as 9. Connect the connector and charge air pipe.
you pull the connector back. Check that the control unit and connector are
clean before assembly. This is to avoid con-
tact problems.
NOTE! When you connect the connector,
press it forwards towards the control unit at
the same time as you press the red catch
arm upwards. This is important, to avoid
damaging the contact pins.

10.Check that the filter is absolutely clean and

that the filter gasket is undamaged. Moisten
the fuel filter gasket with oil.

11.Screw down the fuel filter by hand, until the

gasket just touches the bracket. Then turn it
another half turn by hand

12.Vent the fuel system, please refer to the

“Venting the fuel system“ chapter.

13.Start the engine, check functioning, and

check that no leakage occurs.
4. Undo the charge air pipe from the T-nipple un-
derneath the control unit.
NOTE! Do not unto the T-nipple from the con-
trol unit.

5. Unscrew the rear fuel filter. Use special tool

999 91796 for removal if necessary.
NOTE! Be careful not to spill fuel.

6. Remove the control unit gland underneath the

fixing lug, use a 27 mm spanner.

7. Remove the control unit.

8. Install the new control unit.

Tightening torque: 38 ± 6 Nm

29
Repair instructions

Venting the fuel system

1. Vent screw on filter bracket

2. Hand pump
3. By-pass valve
4. Injector union

NOTE! The fuel system must be vented after the fuel

filter is changed, or after filling the fuel tank when it
has been run dry.

1. Put a suitable vessel underneath the fuel fil- 4. If the injection pump still needs to be vented,
ter. Open the vent screw (1) on the filter loosen the connection for the by-pass valve
bracket. (3) at the pump (the pump can also be vented
by loosening the unions at the injectors (4))
2. Pump up fuel with the hand pump on the until air-free fuel flows out. Tighten the unions
supply pump (2) until fuel flows out, free while fuel is flowing out. Pump another 10 to
from bubbles. Tighten the vent screw while 20 strokes, to build up a suitable supply pres-
fuel is flowing out. sure.

3. Pump another 10 to 20 strokes with the vent 5. Start the engine and check carefully that no
screw closed, to build up a suitable supply leakage occurs.
pressure. Further venting is not normally
needed.

30
 Function check with diagnosis program

The program can read fault codes which have been

stored in the engine control unit, check input and out-
put signals, read off current values from engine sen-
sors, store and print out test results.
The program allows service and workshop personnel to
quickly localise and attend to faults in the EDC sys-
tem.
It is connected to the engine control unit via a diagnos-
tic connector.
User information is included with the program.
Please refer to “Special tools“ to order the software.

31
 Function check with diagnosis instrument
General information
When the control unit receives system voltage, the
control unit checks the system. There is a service/diag-
nostic instrument for the EDC system, to read the re-
sults of checks for diagnosis and function checking.
The instrument makes it easier to quickly localise and
fix any faults in the EDC system.

Diagnosis instrument
The instrument has a window (1) where menus for dis-
playing fault codes, sensor values and input/output sig-
nals are displayed. The menus can be supplemented
and modified, such as other languages in the menus,
by just changing the cassette (5) which contains the in-
strument software.
There are three buttons under the instrument display,
two arrows (2) and (3) and an Execute button
(4) which corresponds to “Enter“ on a computer.

Service/diagnostic instrument

1. Display 4. Execute button (“Enter” on a com-

2. Arrow key, left puter)
3. Arrow key, right 5. Program cassette (change to
change language)

Instruments
Connection
The instrument is connected to a connector on the in-
strument panel.
The installer is responsible for ensuring that this con-
nector is wired in.
Connect the red and black clamps on the diagnostic
instrument cables to the positive (+) and negative (-) Connection of diagnostic instrument
terminals on the engine electrical system, or another
power supply (24 V).

32
 Function check with diagnosis instrument

Instrument menu functions

The instrument has a number of menus stored in its
program section.
The software contains two main sections, choice of
language and choice of menu. The main menu is found
under the choice of menu section, where the user can
get information about current engine speed, coolant
temperature, fuel temperature and fuel consumption.
Under the main menu, there are also menu functions
which allow you to read about the components con-
nected to the control unit, and their status, for example
if the engine has exceeded its pre-set limit values, ba-
sic data about the engine and a diagnostic function
where the fault codes are explained in plain language.
The following instruction summarises all the functions
in the instrument.

Menu operation on the instrument

Choice of language
When the instrument is started, choose language:

• Scroll to relevant language:

For next language, press the arrow
For previous language, press the arrow

• Select relevant language:

Press the execute button when the cor-
rect language is shown on the display.

NOTE! When the language has been chosen, the in-

strument has to be re-started to initialise the new
choice of language
When the language has been chose, the next menu is
displayed automatically. This is the main menu. The
display then shows the first menu underneath the main
menu, which is engine speed.

33
Function check with diagnosis instrument

Main menu
There are 16 sub-menus to choose from the main
menu:
• Engine speed Engine speed
• Control rod
• Absolute pressure
• Temperatures
• Fuel consumption
• Inputs/Outputs
• Engine history
• Operation time
• Basic data
• Charge pressure
• Relative loading
• Battery voltage
• Pre-heating
• Accelerator
• Fault codes
• Nominal engine speed

Menus are selected with the arrow keys.

Choice of menu and sub-menu

• Scroll to relevant menu:
For next language, press the arrow
For previous language, press the arrow

Each menu has one or several sub-menus. To reach

them, press the execute button.

• Choice of sub-menu:
Press the execute button when the cor-
rect menu is shown on the display.

When you have selected the engine speed menu, for

example, and have pressed the execute button ,
the display shows the sub-menu, which is the current
engine speed. If the menu contains several sub-menus,
these are reached by pressing the arrow keys.

• Scroll to relevant sub-menu:

For next sub-menu, press the arrow key

• Display sub-menu:
Press the execute button and the meas-
urement value is shown constantly on the
display.

• Return to main menu:

Press the execute button and the next
menu is displayed.

34
 Function check with diagnosis instrument

Menus with sub-menus

• Engine speed (rpm)
– Engine speed
– Nominal engine speed
• Control rod
– Control rod travel (mm)
– Relative control travel (%)
• Absolute pressure (kPa)

• Temperatures
– Coolant (°C)
– Fuel (°C)
– Charge air (°C)
• Fuel consumption

• nputs/Outputs (Please refer to explanation on

next page)
– In 00000000 00000000
– Out 00000000 00000000

• Engine history

• Operation time (hours:min:sec)

• Basic data
– VShows engine specifications, engine
number, “data set“ (parameter file) part
number, time when it was installed and
where, and by whom, it was programmed.

• Relative loading (0–100%)

– Power developed as a percentage of availa-
ble power

• Battery voltage (V)

• Pre-heating
– Pre-heating time
– Post-heating time
• Accelerator
– Voltage, engine speed control, input (V)
– Relative engine speed control, input (%)
– Frequency (Hz)

35
Function check with diagnosis instrument

Explanation of Input and Output menu

The Input and Output menu shows the components
which supply signals to the control unit and their sta-
tus, by means of ones and zeroes. Using this menu,
faults in the internal function of components or their
cables, connected to the control unit, can be identi-
fied.
When the Input and Output sub-menu is selected, by
pressing the execute button , two lines of ones
and zeroes are displayed, sub-divided into two groups
of eight, one line for inputs and one line for outputs.
The figures represent the following components, start-
ing from the right. (Please refer to the “Sub-menus for
Inputs and Outputs“ illustration).
Inputs:
1. Function button, “Calibration“
2. Function button, “Start“
3. Choice of “Regulator mode”
4. Not active
5. Not active (red)
6. Not active (blue)
7. Function button, pre-heating
8. Not active
9–16. Not used.
Outputs:
1. Main relay
2. Starter relay Sub-menus for Inputs and Outputs
3. Actuation solenoid, control rod
(=1 at working cycle > 0%)
4. Not active
5. Not active
6. Not active
7. Not active
8. Pre-heating relay
9. Lamp for function button, “Regulator mode”
(green)
10.Temperature warning – OUT
11.Lamp for function button, “Diagnosis“
(green)
12.Not active (red)
13.Not active (blue)
14.Not active
15.Not active
16.Not active

36
 Function check with diagnosis instrument

A figure one or zero on the IN line informs about

whether the component has contact with the control
unit or not.
Figure 0 = No contact
Figure 1 = Contact

Example 1. If the seventh figure from the right in the

upper line is a zero, the preheating function button is
disabled. Example 1

A figure one or zero on the OUT line informs about

whether the component is enabled or not.
Figure 0 = Disabled
Figure 1 = Enabled

Example 2. If the eighth figure from the right in the

upper line is a one, the preheating relay is enabled.
(Please refer to the illustration, “Example 2“)
Example 2

Engine history, pre-programmed extreme values

Please refer to the “Component description, Control
unit“ chapter.

Basic data, engine

- Shows engine specifications, engine
number, “data set“ (parameter file) part
number, time when it was installed and
where, and by whom, it was programmed.

37
 Function check with diagnosis button
General information
The EDC system has a diagnosis function which indi-
cates whether the system is functioning normally, via a
combined button and indication lamp marked DIAGNO-
SIS.
The EDC system control unit constantly checks sys-
tem functions. If a technical problem occurs with the
EDC system, or if the system gives unreasonable sig-
nals, the indication lamp will start to flash.

Reading fault codes

If a fault code occurs, the lamp will start to flash. To
read the codes, press the DIAGNOSIS button and
keep it depressed for at lesst 1 second.
A two digit fault code will now be given. First a number
of flashes to indicate the first figure, then a short
pause, and then a number of flashes which indicate
the second figure. DIAGNOSTIC BUTTON
Example:
2 flashes – pause – 4 flashes = fault code 2.4, i.e. a
fault in the engine speed sensor or starter relay.
Please refer to “EDC fault codes“ on the pages below.
When the fault code has stopped flashing, the lamp
will go out. Next time the button is pressed, the next
fault code will be flashed out. The first fault code will
be flashed out again once all fault codes have been
read off.
NOTE! If the diagnosis has triggered any action (e.g.
stopped the engine), the fault code must be erased be-
fore the engine can be started again. Please refer to
“Erasing fault codes“ below.

Erasing stored fault codes

1. Turn off the system voltage with the ignition switch.

2. Press the DIAGNOSIS button and keep it de-

pressed at the same time as you switch the sys-
tem voltage on again with the ignition key. Then
keep the switch depressed for a further 3 seconds.
The fault codes are now erased.

38
 EDC fault codes

Code Meaning Reason Reaction Action

1.1 No fault Diagnostic function activated — —

Accelerator position does not coincide
1.2 Calibration erased —
with engine speed. If it is the accelerator potentiometer: refer to “Calibrating
accelerator linkage“, or re-start

1.3 Fault in accelerator linkage Too small difference between min and — Check fixing of potentiometer in accelerator linkage.
during calibration full throttle resistance values. Erase fault code. Re-calibrate linkage.

2.2 Control rod sensor Control rod position sensor gives Check connections oninjection pump Erase fault code. Start the engine.
unreasonable values to control unit. and control unit
Engine stopped by system

2.3 Control rod actuator Control rod actuator pulls too much or
not enough current. Open circuit in Main relay opens (engine Check connections on injection pump and
control unit connector (pin 42) stopped) control unit. Erase fault code. Start the engine.

2.4 Engine speed sensor or Control unit does not receive a signal Engine does not start. Check connections on sensor, control unit and
starter relay from the engine speed sensor starter relay. Erase fault code. Start the engine.

2.5 Engine speed sensor Engine speed sensor gives Engine stopped by system Check connections on pump and control unit.
unreasonable values Erase fault code. Start the engine.

2.6 Accelerator position sensor System does not receive any information Engine runs at a constant 1000 rpm. Check cables/connections on control potentiometer,
from control potentiometer and cables and connections up to control panel.
Erase fault code. Start the engine.

2.7 Accelerator position sensor Accelerator position sensor gives Engine stopped by system Check connections on sensor and control unit.
unreasonable values to control unit Erase fault code. Start the engine.

3.1 Incorrect frequency Accelerator position sensor gives Engine idles Check higher-level system on sensor and control
unreasonable values to control unit unit. Erase fault code. Start the engine.

System assumes that charge air

3.2 Charge air temperature sensor System receives unreasonable Check cables and sensor connector. Check
temperature is 55°C. Can give
values from charge air tempera- sensor. Erase fault code.
marginally impaired performance/
ture sensor
increased exhaust smoke.
39
40

Code Meaning Reason Reaction Action

3.3 Coolant temperature sensor System receives unreasonable values System assumes that engine tempera- Check cables and sensor connector.
ture is 10°C. Can give increased Check sensor. Erase fault code.
from coolant temperature sensor
exhaust smoke on starting.
NOTE! Alarm for high coolant
temperature does not function.
3.6 DIAGNOSIS” button Button has been depressed > 2 minutes – Check cables and button connections.
(EDC control panel) Check button. Check cables and connections up to
control panel. Erase fault code.

4.6 Starter motor relay Short circuit or open circuit in – Check cables and connections to starter relay in distri-
cables / starter relay. bution box. Check starter relay. Erase fault code.

5.1 Main relay Short circuit or open circuit in – Check cables and connections to main relay in
cables / main relay. distribution box. Check main relay.Erase fault code.

5.4 Pre-heating relay Short circuit or open circuit in – Check cables and connections to pre-heating relay in
cables / pre-heating relay. distribution box. Check main relay.
Erase fault code.

If the pressure is too high, the system Check the air filter. Check the pressure pipe from the
5.6 Charge air pressure System receives too high or too low will reduce the amount of fuel injected inlet pipe to the control unit. Check the Waste gate
value for charge air pressure. until the pressure is normalised (turbo valve.Erase fault code.
protection).

6.1 Fuel temperature Fuel temperature is too high. Mass compensation ceases - engine Reduce fuel temperature. Erase fault code. Check
power is reduced. the installation.

6.2 Charge air temperature Charge air temperature is too high. If the air temperature is too high, the Check the intercoolers and the engine bay
system will reduce the amount of fuel temperature. Erase fault code. Check the installa-
injected until the temperature is normali- tion if the engine bay temperature is too high.
sed (engine protection.)

6.3 Engine temperature Engine temperature is too high. If the engine temperature is too high, the Check sensor cables. Erase fault code. Start the
system will reduce the amount of fuel engine.
injected until the temperature is normali-
sed (engine protection.)
 Code Meaning Reason Reaction Action

8.1 Control unit Faulty internal voltages in the control unit. – Erase fault code.

8.2 Control unit - internal sensors Unreasonable values of fuel tempera- If the charge air pressure is unreasonable, Erase fault code.
ture, charge air pressure or the positive the system will assume a charge air
supply voltage inside the control unit is pressure as a function of engine speed.
too low. This can lead to reduced performance and
increased exhaust smoke. If the fuel
temperature is unreasonable, the system
will assume that the fuel temperature is
40°C. If the true temperature is lower, there
is a risk of excessive power delivery.
Higher true temperature causes somewhat
reduced performance.

8.3 Read/write fault in control Internal fault in control unit. – Erase fault code. Re-calibrate linkage.
calibration.

8.4 Control unit – Storage memory The control unit suffers read/write – Erase fault code.
8.5 faults when reading from/writing to the
8.6 internal memory.

9.9 Control unit – Program memory Internal fault in program memory. – Erasing fault code. Disconnect the EDC system
from system voltage for 5 minutes.

Other Warning lamp on instrument panel Excessive coolant temperature If the coolant temperature is too high, the
Check the cooling system
alarms for high coolant temperature. system will reduce the amount of fuel
injected until the temperature is normalised
41
 Electric fault tracing in EDC systems
General information
Before you start electric fault tracing, check the follow- Measurement of control solenoid
ing:
• Fault codes
• Fuel level and filter
• Air filter
• Battery
• Cables (visual)
• Main switch, fuses, connectors
• Relay connections

Electric fault finding can be done on the following com-

ponents:
• Fuel pump control solenoid, engine speed
sensor and position sensor.
• Coolant temperature sensor.
• Charge air temperature sensor.

Do all measurements with a multimeter set for resist-

ance measurement.

Measurement of components in the injection 2. Use a multimeter to measure between pins 2

pump and 7. The multimeter should show
0.6 – 1.1 Ω.

Measurement of position sensor

1. Undo the connector on the injection pump

acutator.

3a.Use a multimeter to measure between pins 1

and 6. The multimeter should show 18 -22 Ω.

42
 Electric fault tracing

Measurement of charge air temperature

sensor

1. Undo the charge air temperature sensor con-

3b. Or use a multimeter to measure between pins nector.
5 and 6. The multimeter should show
18 -22 Ω.
2. Use the multimeter to measure across the
two contact pins on the sensor. The multime-
Measurement of engine speed sensor ter should show the following values at:

60° C .................................................... 1240 ± 42 Ω

90° C ...................................................... 458 ± 20 Ω
120° C ...................................................... 195 ± 10 Ω

NOTE! The sensor is highly sensitive to temperature

changes. It is enough to breathe on it, or hold it in your
hand to get an incorrect measurement value.

4. Use a multimeter to measure between pins 3

and 4. The multimeter should show 0.8 – 1.2
kΩ.

43
Electric fault tracing

Measurement of coolant temperature sensor

1. Undo the coolant temperature sensor connec-

tor.

2. Use the multimeter to measure across the

two contact pins on the sensor. The multime-
ter should show the following values at:

60° C ...................................................... 319 ± 37 Ω

90° C ........................................................ 128 ± 9 Ω
100° C ......................................................... 97 ± 6 Ω
120° C ......................................................... 57 ± 3 Ω

NOTE! The sensor is highly sensitive to temperature

changes. It is enough to breathe on it, or hold it in your
hand to get an incorrect measurement value.

44
45
 Wiring diagrams
TWD740VE

The positions in the illustration of the EDC system are

the same as the positions on the wiring diagram, and
show where each component is located on the engine.

46
 Wiring diagram for TWD740VE engine
Engine (24 V system voltage)
Note. The components in the wiring diagram have the
same numbers as in the perspective diagram on the
previous page.

1. Battery (24 V).

2. Starter motor
3. Alternator
4. Pre-heating relay
5. Starter relay
6. Main relay
7. Stop relay
8. Horn
9. Sensor, coolant level
10. Oil pressure monitor
11. Oil pressure sensor
12. Coolant temperature sensor, instrument
13. Circuit breaker
14. Connector
15. Test connector
16. Control unit
17. Actuation solenoid, EDC
18. Engine speed sensor
19. Position sensor
20. Coolant temperature sensor, EDC
21. Charge air temperature sensor.
22. Starting heater
23. Diode
24. Fuel temperature sensor
25. Charge air pressure sensor
26. Connector
27. Extra equipment

NO = Normally open during operation. Cables shown

with broken lines are not supplied by Volvo Penta Cable
areas not specified = 0.5 mm2.

Cable colours
BL = Blue P = Pink
LBL = Light blue R = Red
BN = Brown SB = Black
LBN = Light brown VO = Violet
GN = Green W = White
GR = Grey Y = Yellow
OR = Orange
47
TWD1231VE

The positions in the illustration of the EDC system

are the same as the positions on the wiring diagram,
and show where each component is located on the
engine.

48
 Wiring diagram for TWD1231VE engine
Engine (24 V system voltage)
Note. The components in the wiring diagram have the
same numbers as in the perspective diagram on the
previous page.

1. Battery (24 V).

2. Starter motor
3. Alternator
4. Pre-heating relay
5. Starter relay
6. Main relay
7. Stop relay
8. Horn
9. Sensor, coolant level
10. Oil pressure monitor
11. Oil pressure sensor
12. Coolant temperature sensor, instrument
13. Circuit breaker
14. Connector
15. Test connector
16. Control unit
17. Actuation solenoid, EDC
18. Engine speed sensor
19. Position sensor
20. Coolant temperature sensor, EDC
21. Charge air temperature sensor.
22. Starting heater
23. Diode
24. Fuel temperature sensor
25. Charge air pressure sensor
26. Connector, Only late models
27. Extra equipment

NO = Normally open during operation. Cables shown

with broken lines are not supplied by Volvo Penta Cable
areas not specified = 0.5 mm2.

Cable colours
BL = Blue P = Pink
LBL = Light blue R = Red
BN = Brown SB = Black
LBN = Light brown VO = Violet
GN = Green W = White
GR = Grey Y = Yellow
OR = Orange
49
50

Control panel, original

1. Junction box 5.Connector
2. Pin insulator, male 1. Negative (-)
3. Pin insulator, female 2. Automatic stop
4. Connector 3. Positive (+)
1. Positive (+) 6. Serial output
2. Negative (-) 7. Accelerator linkage
3. Start 50 8. Level sensor
4. Alternator 61 9. Intermediate relay
5. Coolant level 10. Latching current relay
6. Oil sensor 11. Diagnostic button
7. Temperature sensor 12. Preheating indication
8. Automatic stop oil pressure, 13. Starter button
coolant temperature 14. Interlock button
9. Alarm 15. Stop button
10.Stop 16. Circuit breaker 8 A
11.Pre-heating 17. Circuit breaker 8 A
12.Rev S- sensor 18. Circuit breaker 16 A
13.Rev S+ sensor 19. Joint
20. Charge indication lamp
21. Diagnosis indication
22. Tachometer
23. Coolant temperature instrument
24. Oil pressure instrument
25. Instrument lighting

NO = Normally open during operation.

Cables shown with broken lines are not supplied
by Volvo Penta Cable areas not specified = 0.5
mm2.
Cable colours
BL = Blue P = Pink
LBL = Light blue R = Red
BN = Brown SB = Black
LBN = Light brown VO = Violet
GN = Green W = White
GR = Grey Y = Yellow
OR = Orange
 Control panel layout

Main cables
(24 V system voltage)
Note. The components in the wiring diagram have
the same numbers as in the perspective diagram
on page 45.
1. Starter button
2. Latching relay
3. Stop button
4. Tachometer
5. Coolant temperature gauge
6. Oil pressure gauge
7. Charge warning lamp
8. Pre-heating indication
9. Engine speed potentiometer
10. Diagnostic connector
11. Regulator, position indicator
12. Regulator, position switch
13. Diagnostic button
14. Diagnostic lamp
15. Calibration button
16. Power supply
17. 16 pin connector
18. Fuse
19. Key switch
20. Warning lamp, coolant level
21. Warning lamp, coolant temperature
22. Warning lamp, oil pressure

NO = Normally open during operation.

Cables shown with broken lines are not supplied by
Volvo Penta Cable areas not specified = 0.5 mm2.

NOTE! The higher-level cable installation is a rec-

ommendation from Volvo Penta. Cable colours etc.
are the customer’s responsibility.
51
 Notes

52
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AB Volvo Penta
Customer Support
Dept. 42200
SE-405 08 Gothenburg
Sweden
7738217-4 English 06-2002