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Volvo Diesel Engine Control System Installation

May. 03, 2018

Volvo Diesel Engine Control System Installation

 

Connection

General

• The installation must be prepared for well and carried out with the greatest care.

• Secure the connecting cable between the engine and instrument panel with clamps. Bear in mind that connector blocks must be mechanically secured so that they are not exposed to any pulling forces.

• The cables must not be run close by hot engine components or close to any other heat source.

Ensure that the cables are protected from mechanical wear, sharp edges and water splashes. If necessary, the cables can be run through conduits.

• As far as possible, avoid splices in the system wiring.

The cables and any splices must be accessible for inspection and service.

NOTICE! Connectors must be assembled “dry”, they must not be filled with petroleum jelly or similar.

 

Power supply

NOTICE! The engines are equipped with 2-pole electrical systems. This means that the battery negative cable must be connected to the engine block or the flywheel housing.

The battery positive cable may be run via a main switch to terminal 30 on the starter motor.

The battery negative cable must be connected to the engine block or the flywheel housing, close to the starter motor. Refer to the illustration below.


P0004300.jpg


 

Battery specification

Max. battery 2x220 Ah (series connected), 1150 A CCA EN.

Battery charging

Standard for all engines is that batteries are supplied with power from the alternator

Battery cable cross-sectional area

The total length (L) of the positive and negative cables determines cable cross sectional area (A).

 

Max L

(m)

(ft)

8

26.2

10

32.8

13

42.6

Min A

(mm2)

(in2)

70

0.11

95

0.15

120

0.19

 

WARNING!

Due to fire risk, the cable area should never be less than 70 mm2 (0.1 inch2).

 

 

Engine control

Refer to System Information page 33 CIU

NO = normally open

NC = normally closed

Start lock (system voltage OFF / ON)

Engine system voltage start current (control unit) is 10

A. Ensure that other components in the installation are dimensioned for this current load.

Start switch

Switch type: closing (NO), spring loaded.

Stop switch

Switch type: closing (NO), spring loaded.

The stop switch is energized during operations via a parameter setting. In this case use a normally closed

(NC) switch.

RPM potentiometer

Nominal revolutions minus 120 rpm: 0.3–1.9 V (preset value 1.17 V)

Nominal revolutions plus 120 rpm: 1.9–4.7 V (preset value 4.5 V)

P0005827.jpg

P0005828.jpg



 

1500/1800 rpm switch

Two-position contact.

This function allows a frequency change from 50 to 60 Hz.

Idle switch

Two-position contact.

Closed contact provides idle rpm.

Droop value switch

Two-position contact.

The switch must be closed to provide rpm droop value.

Primary control switch

Two-position contact.

Contact, pre-heating

Two-position contact.

 

Instruments

Easy Link Instrument (option)

Refer to the System Information page 33 for the engine concerned.

For parallel connection of up to 20 extra VDO instruments.

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


P0005054.jpg



The following instruments are available:

• Tachometer/operating hours

• Coolant temperature

• Oil pressure

• Oil temperature

• Battery voltage

 

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Instrument, analog (option)

Refer to the System Information page 33 for the engine concerned.

Tachometer

Use Volvo Penta standard tachometer, graduations 0–2600 rpm. Setting code 14. Refer to installation instructions.


P0003961.jpg

 

Oil pressure gauge

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

 

Oil temperature gauge

Use Volvo Penta oil temperature gauge, graduations 40–150 °C (104–302 °F).

 

 

Coolant temperature gauge

Use Volvo Penta oil temperature gauge, graduations 40–150 °C (105–300 °F).

Diagnostics switch Switch type: closing (NO), spring loaded. For reading fault codes, refer to the Calibration and Settings page 72 chapter.

Contact, pre-heater

Switch type: closing (NO), spring loaded. This contact

activates the pre-heating.


 P0003961.jpg


Synchronizing Engine Speed

Synchronization/load distribution

The system is adapted for GAC synchronization and load distribution. Use the EAM122 interface module when connecting to this system. When this system is used, voltage levels must be adjusted simultaneously with VODIA, according to the below.


P0005829.jpgP0003964.jpg



NOTICE! The EAM122 interface module is not sold by Volvo Penta. Contact a GAC (Governors of America Corporation) dealership.

 

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