Volvo Penta IPS EVC-C Group 30 Electrical System Workshop Manual_77983060 – PDF DOWNLOAD

Volvo Penta IPS EVC-C Group 30 Electrical System Workshop Manual_77983060 – PDF DOWNLOAD

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Volvo Penta IPS EVC-C Group 30 Electrical System Workshop Manual_77983060 – PDF DOWNLOAD

Language : English
Pages : 290
Downloadable : Yes
File Type : PDF
Size: 1.2 MB

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Volvo Penta IPS EVC-C Group 30 Electrical System Workshop Manual_77983060 – PDF DOWNLOAD

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 details might not correspond with other engines in some cases.

• Repair methods are similar in all important respects, 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 correspondence about any product.
• The Workshop Manual is produced primarily for the use of Volvo Penta workshops and service technicians. 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 subject 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.

TABLE OF CONTENTS:

Volvo Penta IPS EVC-C Group 30 Electrical System Workshop Manual_77983060 – PDF DOWNLOAD

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