Volvo TAD734GE, User Manual

Page 1: ...Users guide and maintenance manual V VO OL LV VO O D Di ie es se el l e en ng gi in ne e T TA AD D7 73 34 4G GE E E EM MS S 2 2 7747302 English03 2007 33522069101_0_1 ...

Page 2: ......

Page 3: ...TAD734GE EMS 2 OPERATOR S MANUALp ...

Page 4: ...y applications under some of the most rigorous conditions imaginable This is not by chance After more than 90 years of producing engines the name Volvo Penta has come to symbolize reliability technical ingenuity first class perfor mance and longevity We believe that these characteristics are also ultimately your requirements and expectations for new Volvo Penta industrial engines To make certain t...

Page 5: ...er use start spray 23 Starting with auxiliary batteries 23 Running 24 CheckGauges 24 Fault indication 24 Operation at low load 24 Stopping the engine 25 Beforestopping 25 Stop 25 After stopping 25 Auxiliary stop 25 Maintenanceschedule 26 Maintenance 28 Engine general 28 Lubrication system 30 Cooling system 33 Fuel system 38 Electrical system 41 Shutdown 44 Preservation 44 Restoration 45 Troublesho...

Page 6: ...alfunctions if the instruction is ignored IMPORTANT Is used to call attention to things which could cause damage or malfunctions to product or property NOTE Used to draw your attention to important information that will facilitate the work or operation in progress This symbol is used on our products in some cases and refers to important information in the instruction book Make sure that warning an...

Page 7: ... When engines are supplied without touch guards all rotating components and hot surfaces must be pro tected after installation in their application if neces sary for personal safety Ignition Lock If the instrument panel does not have a key switch the engine compartment must be lockable to prevent unauthorized persons from starting the engine Alter natively a lockable main switch can be used Mainta...

Page 8: ...micals are flammable Always read and follow the directions on the packages Work on the fuel system must be done with the en gine cold Fuel leakages and spills on hot surfaces or electrical components can cause fires Store oil and fuel soaked rags and other flammable material in such a way that there is no danger of them causing fire In certain circumstances oil soaked rags can spontaneously ignite...

Page 9: ...e filler cap completely and starting work Note that the coolant can still be hot and cause burns Fuel System Always protect your hands when searching for leaks Fluids which leak under pressure can force their way into body tissue and cause severe injury There is a risk of blood poisoning septicemia Always cover the alternator if it is located beneath the fuel filters Fuel spillage can damage the a...

Page 10: ... engine in normal operation Full load should only be applied for short periods Never run the engine at constant revolutions for prolonged periods during running in Higher oil consumption is normal during the first 100 200 hours of operation For this reason check the oil level more frequently than the normal reccomendation When an disengageable clutch is installed this should be checked more carefu...

Page 11: ... the engine may not be broken by un authorized persons Otherwise the general instructions in the Operator s Manual regarding operation maintenance and service apply IMPORTANT Neglectedorinferiormaintenance service or the use of non original spare parts will result in AB Volvo Penta no longer accepting responsibity for engine conformity with the certi fied model Damage injury and or costs which ari...

Page 12: ...able wet cylinder liners Cast aluminum pistons with oil cooling Three piston rings with a keystone type top ring Induction hardened overhead camshaft with valve lifters and push rods Four valves per cylinder Replaceable valve seats and valve guides Control Unit Microprocessor based fuel supply control unit EMS 2 Fuel System Common rail fuel injection Gearwheel fuel feed pump camshaft driven EMS 2 ...

Page 13: ...I approval 7 Rated power standard peak power according to Tier III 8 Air temperature in C F in accordance with ISO 3046 9 Altitude above mean sea level in accordance with ISO 3046 10 EU Tier III approval number Location of Engine Plates The engines are supplied with two engine plates of which one is situated on the right side of the engine block and the other on top of the valve cover Engine Plate...

Page 14: ...nt outlet from thermostat housing 9 Fan hub 10 Alternator 11 Drive belt 12 Damper and belt pulley 13 Oil pan 14 Tensioner pulley 15 Coolant inlet to engine 16 Drain plug oil pan 17 Oil Cooler 18 Coolant pump 19 Outlet engine heater option 20 Dipstick 21 High pressure pumps 22 Air inlet pipe 23 Valve cover 24 Indicator air filter 25 Fuel pump 26 Flywheel housing 27 Starter motor guard 28 Charge air...

Page 15: ...temperature 3 Water in fuel mounted on fuel pre filter 4 Charge air pressure and temperature 5 Pre heating inlet air 6 Fuel pressure in distributor manifold Rail 7 Fuel pressure 8 Oil pressure sensor 9 Relay 10 Rpm sensor flywheel 11 Rpm sensor camshaft NOTE Positions may differ depending on the engine model ...

Page 16: ...n trouble shooting Fault codes can also be deciphered by Volvo s VODIA tool at au thorized Volvo Penta workshops If there is a serious malfunction the engine will be shut down altogether or the control unit will reduce available power depending on the application Once again a fault code will be generated for guidance in trouble shooting Summary The system comprises among other things of a con trol...

Page 17: ...ink instruments are available Engine rpm hour meter fault codes are also dis played on the tachometer display when the diag nostic button is pressed Coolant temperature Oil pressure Turbo pressure Battery voltage Alarm panel DU Display Unit The DU is an instrument panel which shows engine working values graphically on an LCD screen It con sists of an computerised unit for permanent installa tion i...

Page 18: ...eck and in some cases to set a number of different functions in the EMS system NOTE The menus and illustrations shown here are from the English version The language can be changed how ever refer to the Setup menu 1 LED display 2 START Starts the engine 3 SPEED Reduces engine rpm 4 SPEED Increases engine rpm 5 STOP Stops the engine 6 ON OFF Starts and stops the system 7 Scrolls down in menus 8 SEL ...

Page 19: ...heating OBS Must be activated when the temperature is below 0 n Governor mode activates droop n Diagnostics shows fault codes in text n Trip reset restores trip data n Setup parameter setting n Information shows the data for the applicable hardware software data set and engine identifica tion of the engine and DCU Engine data shows relevant engine data Engine rpm can be controlled with the SPEED a...

Page 20: ...tarting proce dure EMS 2 Press SEL the text Preheat requested is dis played The display automatically returns to the Engine Data menu Governor mode activates deactivates droop To set the droop level refer to the Setup Governor gradient or Govenor droop Select Isochronous mode or Droop mode with the SEL button Diagnostics shows the error list containing the 10 latest active and inactive faults The ...

Page 21: ... stop input must be connected to volt age to stop the engine Run The stop input must be connected to volt age to run the engine Customer parameter alarm threshold limits Re fer to Customer parameter Versatile and Cus tomer parameter Genset Throttle input setting setting rpm control and voltage limits See Throttle input setting Display setting display settings See Display setting Customer parameter...

Page 22: ... at excess rpm alarm Refer to Overspeed limit to activate the alarm limit for the excess rpm alarm Oil temp warning limit C setting oil tempera ture alarm limit TAD734 sender not fitted Coolant temp limit C setting coolant tem perature alarm limit Throttle input setting rpm control setting throttle operation Set throttle mode OFF rpm is controlled via the DCU panel ext throttle input rpm is regula...

Page 23: ...rightness sets backlight bright ness Information displays engine and DCU data Engine hardware Id engine control unit article number Engine software Id engine control unit software article number Engine dataset1 Id article number engine dataset 1 Engine dataset2 Id article number engine dataset 2 Vechicle Id chassis number DCU hardware Id DCU article number DCU software Id DCU software article numb...

Page 24: ...there is no evidence of oil fuel or cool ant leaks present Check the air filter pressure drop indicator Refer to the Maintenance Engine General chapter Check the coolant level and that the radiator is not blocked externally Refer to the Maintenance cooling system chapter WARNING Do not open the expansion tank cap when the engine is hot Steam or hot fluid could spray out Turn the main current on IM...

Page 25: ... NOTE Preheat must be activated when the tempera ture is below 0 With preheating 1 Pess the ON OFF button 6 2 Press the SEL button 7 to come to the main menu 3 Navigate to Preheat with button 9 Press the SEL button 7 4 In the preheat menu press the SEL button 7 again to select pre heating the text Preheat ac tive please wait is shown in the display 5 Wait until the text disappears and then press t...

Page 26: ...mmended viscosity for the prevailing tempera ture should be used Refer to the Maintenance lubri cation system chapter Synthetic lubricants withstand wider temperature ranges than mineral based lubri cants Preheat the coolant with a separately installed electric engine heater In extreme cases a diesel burning en gine heater may be needed Ask your Volvo Penta dealer for advice IMPORTANT Make sure th...

Page 27: ...y batteries are connected series or parallel so that the rated voltage corre sponds to the engine system voltage 2 First connect the red jumper cable to the auxil iary battery then to the discharged battery Then connect the black jumper cable to the auxilliary battery and finally to a place a short distance from the discharged batteries e g the main switch negative cable or the negative cable s st...

Page 28: ...Avoid long term operation at idle or at low load since this can lead to increased oil consumption and even tually to oil leakage from the exhaust manifold since at low turbo pressures oil will seep past the turbo charger seals and carry over with the charge air into the inlet manifold As a consequence of this carbon builds up on valves and piston crowns and in exhaust ports and the ex haust turbin...

Page 29: ...ng In this manner temperatures are evened out and hotspots are avoided while at the same time the turbocharger cools a little This will contribute to long service life without malfunctions Stop Disengage the clutch if possible Press the STOP button turn the key to S After stopping Check the engine and engine compartment for signs of leakages Turn off the main switches during longer stop pages Carr...

Page 30: ...ade every 8 hours After the first 100 200 running hours Valve clearance check not shown Injectors re tighten 50 Nm not shown After the first 150 running hours Engine oil and oil filter change 1 2 page 32 1 Oil change intervals vary depending on oil grade and sulfur content of the fuel Refer to Lubrication system 2 The oil filter must be replaced at every oil change Every 50 running hours Battery c...

Page 31: ... 29 Every 1000 running hours Charge air pipe leakage check page 28 Fuel filters replacing page 40 Every 1500 running hours Valve clearance inspection adjustment not shown Every 2000 hours or every 12 months Inspection air compressor change not shown Air filter cleaning1 not shown 1 When operating in extremely dirty conditions cleaning must take place often Every 2400 running hours Turbocharger che...

Page 32: ...fter oper ations when the engine is stopped This will help you to discover quickly if anything abnormal has hap pened or is about to happen Look especially carefully for oil fuel and coolant leak ages loose bolts worn or poorly tensioned drive belts loose connections damaged hoses and electri cal cables This inspection only takes a few minutes and can prevent serious malfunctions and expensive rep...

Page 33: ...nd drive belts have automatic belt tensioners and do not need to be adjusted Check the condition of the belts Change as necessary refer to Alternator belt change and Drive belt change 1 Release the belt tensioner and lock it in place with a mandrel 1 2 First remove the belts 2 from the coolant pump 3 Install the new belt Release the belt tensioner Check that the belts are correctly aligned in thei...

Page 34: ...rements above 1 If sulfur content is 1 0 by weight use oil with TBN 15 2 Lubrication oil must comply with both requirements Note API CG 4 or CH 4 can be approved in markets outside Europe instead of ACEA E3 VDS Volvo Drain Specification ACEA Association des Constructeurs Européenne d Automobiles API American Petroleum Institute TBN Total Base Number Lubrication System Sulfur percentage in fuel by ...

Page 35: ...d be checked every 24 hours WARNING Approaching or working on a running engine is a safety risk Watch out for rotating components and hot surfaces Viscosity Select the viscosity from the adjacent table for the ap propriate continuous ambient air temperature Denotes synthetic or semi synthetic oils Oil change volume Refer to the Technical Data chapter ...

Page 36: ...fill over the MAX level 7 Start the engine and let it idle Check that the oil pressure is normal 8 Stop the engine Check that no oil leakage occurs around the filters Top up with oil as nec essary Oil filter Change Change the oil filters during each oil change WARNING Hot oil and hot surfaces can cause burns 1 Drain the oil according to the instructions in En gine oil Replacement NOTE Position a s...

Page 37: ...itable chemical composition must be used all year round This applies even if there is no risk for frost damage so that the engine has complete corrosion protection Future warranty claims on the engine and ancillaries may be rejected if an unsuitable coolant has been used or if the instructions concerning coolant mixing have not been adhered to NOTE Corrosion protection additives become less effect...

Page 38: ...nd increase the risk of overheating and frost damage IMPORTANT The coolant must be mixed with pure water use distilled de ionized water The water must fulfill the requirements specified by Volvo Penta see Water quality IMPORTANT It is extremely important that the correct concentration of coolant is added to the system Mix in a separate clean vessel before filling the cooling system Make sure that ...

Page 39: ...he cooling system refer to Coolant mixing Filling a completely empty system Filling should be done with the engine stopped Fill up slowly to allow the air to flow out The system is vented automatically Fill up with coolant to the correct level Do not start the engine until the system is vented and com pletely filled Start the engine and warm it up until the thermostats are open about 20 minutes Op...

Page 40: ...l 1 Position a suitable vessel underneath the drain plug 1 and undo the plug 2 Let the coolant run out IMPORTANT Deposits which must be cleared away may be found inside the drain plugs taps Check that all coolant really does drain out 3 Screw the drain plug back 1 Charge air cooler External cleaning Remove guards as necessary to access the radiator Clean with water and a mild detergent Use a soft ...

Page 41: ... material from settling back in the system emptying should be done rapidly within 10 minutes without the engine standing still for a long time Remove the filler cap and if necessary the lower radiator hose to increase emptying speed 6 Flush the system immediately and thoroughly with clean hot water to prevent dirt from resettling on the inner surfaces Flush until the water that runs out is complet...

Page 42: ...t cause a fire Fuel specification At a minimum fuel must comply with national and international standards regarding marketable fuels NOTE Bio diesel according to EN 14214 kersosene and light fuel oil may not be used The following fuel standards are approved EN590 with nationally adapted environmental and coldstandards ASTM D975 No 1 D 2 D JIS KK 2204 may only be used if lubricity corresponds to EN...

Page 43: ...Test run the engine and check that no leakage occurs Fuel pre filter change Filter inserts must be changed in accordance with the maintenance schedule recommendations 1 Stop the engine and open the fuel tap 2 Unscrew the water reservoir and empty any water 3 Unscrew the filter cartridge 4 Check that the filter cartridge is absolutely clean and that the seal is undamaged Applya film of oil on the g...

Page 44: ... NOTE Do not fill the new fuel filter with fuel before assembly there is a risk that contamination could get into the system and cause malfunctions or damage WARNING The fuel filter must be changed when the engine is cold to avoid the risk of fire due to spilled fuel on hot surfaces 1 Clean round the fuel filter 2 Remove the filter 1 with a suitable filter re mover Collect any spilled fuel in a co...

Page 45: ...started or if the instrument panel stops working during operation the fuse may have blown Check and replace fuses or re set circuit breakers IMPORTANT Always investigate the reason for theoverload Main switch The main switch must never be switched off before the engine has been stopped If the circuit between the alternator and the battery is broken when the en gine is running the alternator can be...

Page 46: ...t connect the cable red to the pole on the battery Then connect the cable black to the pole on the battery When you disconnect batteries connect the cable black first then the cable red Cleaning Keep the batteries dry and clean Contamination and oxide on the batteries and battery posts can cause stray currents voltage drop and discharge especially in wet weather Clean oxidation from the battery po...

Page 47: ...arged if necessary refer to the battery manufacturer s rec ommendations Batteries are damaged by being left discharged and can also freeze and burst more easily in cold weather IMPORTANT Follow the battery charger instruc tion manual carefully To avoid the risk of elec trochemical corrosion when an external charger is connected the battery cables should be re moved from the batteries before the ch...

Page 48: ...oses or electrical components Preservation For shutdowns of up to 8 months change the oil and engine oil filters and afterwards run the engine until warm For shutdowns longer than 8 months Treat the lubrication and fuel systems with preser vation oil Refer to the instruction on the next page Check that the coolant offers sufficient frost pro tection Top up as necessary Alternatively drain the cool...

Page 49: ...ged during conservation Install new fuel filters and vent the fuel system Check the drive belt s Check the condition of all rubber hoses and re tighten the hose clamps Start the engine and run at a fast idle until about 2 liters of the fluid in the cannister have been used Stop the engine and connect the perma nent fuel pipes Drain the preservative oil from the engine To continue follow the instru...

Page 50: ... low 20 No or poor charge 2 23 1 Dischargedbatteries 2 Poor contact open circuit in electrical cable 3 Main switch turned off 4 Faulty ignition lock 5 Faulty main relay 6 Faulty starter motor relay 7 Faulty starter motor solenoid 8 No fuel fuel cocks closed fuel tank empty wrong tank connected 9 Blocked fuel filter pre filter because of contamination or paraffin fraction separation in fuel at low ...

Page 51: ...ges via the instruments Both active unactioned and passive actioned faults are stored in the control unit Refer to the Operation heading for deciphering fault codes fault messages All fault codes and fault messages are found in the fault code list with information about the reason reac tion and measures to be taken refer to the Fault codes chapter NOTE All instruments are accessories Active faults...

Page 52: ... is set the following text is shown on the display ENGINE WARNING alternated with Press SEL for information NOTE You can choose the language that the informa tion is presented in Read the fault code as follows 1 Press the SEL button to come to the fault list The fault list shows Running hours Fault message Active inactive 2 Look up the fault code in the list in the Fault Code chapter and take the ...

Page 53: ...ollows 1 Press the diagnostic button 2 Release the diagnostic button and make a note of the fault that is flashed out 3 Repeat items 1 2 A new fault code is flashed out if more are stored Repeat until the first fault code is repeated NOTE When the first fault code recurrs all the fault codes have been read If the diagnostics button is depressed after the fault has been corrected and the fault code...

Page 54: ...de 2 2 PID SPN 111 Coolant level Reason Low coolant level Reaction Engine control unit reduces engine power unless the protection has been shut off with the VODIA diagnostic tool Engine stopped Action Check the coolant level Check coolant level monitor function Code 2 3 PID SPN 111 Coolant level sensor Reason Short circuit to positive Fault in sensor Reaction None Action Check that the coolant lev...

Page 55: ...eck that the potentiometer is correctly con nected Check that the potentiometer cable is not dam aged Check potentiometer function Code 2 9 PID SPN 97 Indicator for water in fuel Reason Short circuit Open circuit Fault in indicator Reaction None Action Check the indicator cables for breaks and short circuits Check indicator function Change indicator as nec essary Code 3 1 PID SPN 100 Oil pressure ...

Page 56: ... temperature sensor function Code 3 5 PID SPN 106 102 Charge pressure Reason Charge pressure too high Reaction Engine control unit reduces engine power unless the protection has been shut off with the VODIA diagnostic tool Action Check turbocharger compressor function Check charge air temperature sensor function Check fuel volume injector Code 3 6 PID SPN 94 Fuel pressure sensor Reason Short circu...

Page 57: ... The engine starts as soon as the ignition is switched on Action Check that the starter switch connections are not damaged Check that the wiring to the starter key is not damaged Code 5 3 PPID 6 SPN 520195 Stopp input CIU Reason Short circuit to negative Open circuit Activated for too long Reaction Engine can only be stopped with the auxiliary stop AUX STOP on engine Engine stops A fault code is d...

Page 58: ...s not damaged Check that the cables between the CIU and the engine control unit are not damaged Code 6 5 SID 231 SPN 639 2017 PSID 201 Data link CAN EMS 2 Reason Internal fault in control unit Reaction Engine not operating engine cannot be started Engine running engine idles and can only be stopped with the auxiliary stop AUX stop Action Check that the 8 pin connector is not damaged Check that the...

Page 59: ...am aged Check fuel supply pressure Check the valve clearance Perform a compression test and check cylinder 2 Code 7 3 SID 3 SPN 653 Injector cylinder 3 Reason Electrical fault Faulty compression or injector Reaction Engine runs on 5 cylinders Abnormal sound Reduced performance Action Check that the unit injector cables are not dam aged Check that the injector connections are not dam aged Check fue...

Page 60: ... the injector connections are not dam aged Check fuel supply pressure Check the valve clearance Perform a compression test and check cylinder 6 Code 8 3 SID 42 SPN 679 Injectionpressure regulator Reason Faulty cables Faulty actuator Fault in MPROP Reaction Engine contril unit limits engine power Action Contact an authorized Volvo Penta workshop Code 8 3 PSID 96 SPN 1239 Pressure in distribution ma...

Page 61: ...ction Not possible to activate preheating Action Check cables Check the preheating relay Code 9 3 SID 232 221 SPN 620 1079 1080 Voltage supply to sensor Reason Short circuit Fault in one of sensors Reaction Faulty values in oil pressure and charge air pres sure sensors Fault code for oil pressure and charge air pressure sensors Low power Oil pressure and oil temperature instruments show 0 Action C...

Page 62: ...ason Memory fault in engine control unit EMS Reaction Engine might not start Action Re program the unit Code 9 9 SID 254 SPN 629 Control unit EMS Reason Internal fault in control unit Reaction Engine misfires Engine does not start Action Change engine control unit ...

Page 63: ...fer to the sales literature No of cylinders 6 Bore 108 Stroke mm 130 Cylinder volume dm3 7 15 Weight app kg 764 Weight app kg 954 Weight wet kg 788 Weight wet GenPac kg 1021 Firing order 1 5 3 6 2 4 Compressionratio 17 1 Low idle rpm 900 High idle rpm 1500 1800 only engine excluding cooling system ...

Page 64: ...ng change of filters oil pan standard 29 liter 7 7 US gallon Oil pressure with engine oil at operating temperature min 120 C At rated engine rpm 420 450 kPa 61 65 psi Automatic stop at pressure less than 100 kPa 15 psi Oil grade Refer to the specification under Maintenance Viscosity Refer to the specification under Maintenance Oil filters full flow filter Number 1 tighten 1 2 3 4 turn after it jus...

Page 65: ...ge max current density 28V 80A Cooling System Type Pressurized sealed Pressure valve max opening pressure 120 kPa 17 4 psi Volume engine TAD734GE 8 liter 2 11 US gal Thermostat Quantity and type 1 pc piston thermostat Openingtemperature 83 C 181 F Fully open at 103 C 217 F ...

Page 66: ...Notes ...

Page 67: ...oder als Fax an Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Schweden Fax 46 31 545 772 Die Bestellung kann auch über das Internet erfolgen http www volvopenta com manual coupon Ja ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten Publikationsnummer 7747303 Name Anschrift Land 42200 615001 155099900192 Noter que l offre est valable 12 mois ...

Page 68: ...a la misma es válida siem pre que haya existencias Franquear o enviar fax a Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Suecia Fax 46 31 545 772 El pedido puede hacerse tam bién por internet http www volvopenta com manual coupon Sí gracias deseo recibir gratuitamente un libro de instrucciones en español Número de publicación 7747305 Nombre Dirección País 42200 ...

Page 69: ...ution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Ruotsi Fax 46 31 545 772 Tilauksen voi tehdä myös Internetissä http www volvopenta com manual coupon Kyllä kiitos haluan suomenkielisen ohjekirjan veloituksetta Julkaisunumero 7747307 Nimi Osoite Maa 42200 615001 155099900192 Notar que a oferta é válida por um período de 12 meses a partir da data de entre ga do motor Depois desse per...

Page 70: ...20 SE 405 08 Göteborg Sweden Fax 46 31 545 772 Ìðïñåßôå åðßóçò íá äþóåôå ôçí ðáñáããåëßá óáò ìÝóù ôïõ Internet óôç äéåýèõíóç http www volvopenta com manual coupon Íáé Èá Þèåëá Ýíá áíôßôõðï ôïõ åã åéñéäßïõ ñÞóçò óôçí áããëéêÞ ãëþóóá ùñßò êáìéÜ ñÝùóç Áñéèìüò Ýêäïóçò 7747310 íïìá Äéåýèõíóç þñá 42200 615001 155099900192 12 Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg ...

Page 71: ......

Page 72: ...7747302 English 03 2007 ...