volvo diesel engine tad734ge ems 2info.bm.ee/tech/gendata/v275/engine/33522069101.pdf · users...

Users guide and maintenance manual

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TTAADD773344GGEE EEMMSS 22

7747302 (English03-2007) 33522069101_0_1

TAD734GE (EMS 2)

OPERATOR’S MANUALp

Engine data

Engine designation ........................... Product number ....................................

Serial number .........................................................................................................

Clutch, type/nr. .......................................................................................................

Nearest Volvo Penta service location

Name .......................................................................... Telephone ....................

Address ...................................................................................................................

© 2007 AB VOLVO PENTAVolvo reserves the right to make changesPrinted on environmentally friendly paper

ForewordVolvo Penta industrial engines are relied upon throughout the world,in both mobile and stationary applications, under some of the mostrigorous conditions imaginable. This is not by chance.

After more than 90 years of producing engines the name Volvo Pentahas come to symbolize reliability, technical ingenuity, first-class perfor-mance and longevity. We believe that these characteristics are alsoultimately your requirements and expectations for new Volvo Pentaindustrial engines.

To make certain that your expectations are matched, we ask thatyou read carefully through the instruction book before startingthe engine.

Sincerely

AB VOLVO PENTA

Safety information ................................................. 2Safety precautions for operationand maintenance.................................................. 3

Introduction ........................................................... 6Environmental care ............................................... 6Running in ............................................................. 6Fuel and oils ......................................................... 6Maintenance and spare parts ................................ 6Certified engines ................................................... 7Warranty ................................................................ 7

Presentation .......................................................... 8Technical description ............................................ 8Identification numbers ........................................... 9Component location ............................................. 10Location of sensors .............................................. 11EMS 2 ................................................................ 12Instrument, EMS 2 ............................................... 13DCU (Display Control Unit) ................................... 14

Starting the engine .............................................. 20Before starting ................................................... 20Start routine (DCU) ............................................. 21Starting in extreme cold ..................................... 22Never use start spray ......................................... 23Starting with auxiliary batteries .......................... 23

Running ............................................................... 24Check Gauges ................................................... 24Fault indication................................................... 24Operation at low load ......................................... 24

Stopping the engine ........................................... 25Before stopping .................................................. 25Stop ................................................................... 25After stopping .................................................... 25Auxiliary stop ...................................................... 25

Maintenance schedule ........................................ 26

Maintenance ........................................................ 28Engine, general ................................................... 28Lubrication system ............................................... 30Cooling system ................................................... 33Fuel system ........................................................ 38Electrical system ................................................ 41

Shutdown ............................................................ 44Preservation ........................................................ 44Restoration ......................................................... 45

Troubleshooting .................................................. 46

Diagnostic function ............................................. 47Fault notification ................................................. 47Effect on the engine ............................................ 47Operation ............................................................ 48Reading fault codes ............................................ 48

Fault codes .......................................................... 50

Technical data ..................................................... 59General ............................................................... 59Lubrication system .............................................. 60Fuel system ........................................................ 60Cooling system ................................................... 61Electrical system ................................................ 61

Table of contents

2

Safety information

Incorrect operation can lead to personal injury and damage to products or property. Thereforeread through the instruction book very carefully before you start the engine or do any mainte-nance or servicework. If there is still something which is unclear or you are unsure of, pleasecontact your Volvo Penta dealer for assistance.

This symbol is used in the instruction book and on the product, to call your attentionto the fact that this is safety information. Always read such information very carefully.

Safety texts in the instruction book have the following order of priority:

WARNING! Warns for the risk of personal injury, major damage to product or property, orserious malfunctions if the instruction is ignored.

IMPORTANT! Is used to call attention to things which could cause damage or malfunctionsto product or property.

NOTE!Used to draw your attention to important information that will facilitate the work oroperation in progress.

This symbol is used on our products in some cases and refers to important information inthe instruction book. Make sure that warning and information symbols on the engine are clearlyvisible and legible. Replace symbols which have been damaged or painted over.

Read this chapter very carefully. It has to do with your safety. It describes how safety information is presented inthe instruction book and on the product. It also gives you an overview of the basic safety precautions for maintain-ing the engine.

Check that you have received the correct operator’s manual before you read on. If not, please contact yourVolvo Penta dealer.

Safety information

3

Safety precautions for operation and maintenance

Daily ChecksMake a habit of always checking the engine compart-ment before running (before the engine is started)and after running (when the engine has beenstopped). This helps you to quickly discover whetherany leakage of fuel, coolant, oil or any other abnormalevent has happened, or is about to happen.

Fuel FillingThere is always a risk of fire and explosion when refu-eling. Smoking is forbidden, and the engine must bestopped.

Never over-fill the tank. Close the tank cap securely.

Only use the fuel recommended in the instructionbook. The wrong grade of fuel can cause malfunctionsor stop the engine. In a diesel engine, it can alsocause the injection pump to bind and the engine toover-rev, entailing a strong risk of personal injury andmachinery damage.

Carbon Monoxide PoisoningOnly start the engine in a well-ventilated area. Whenrunning in a confined space, exhaust fumes andcrankcase gases must be led away.

OperationThe engine must not be operated in environmentswhich contain explosive media since none of the elec-trical and mechanical components are spark proof.

Approaching a running engine is a safetyrisk. Hair, fin-gers, loose clothes, or dropped tools can catch on ro-tating components and cause severe injury.

When engines are supplied without touch guards, allrotating components and hot surfaces must be pro-tected after installation in their application, if neces-sary for personal safety.

Ignition LockIf the instrument panel does not have a key switch,the engine compartment must be lockable, to preventunauthorized persons from starting the engine. Alter-natively, a lockable main switch can be used.

Maintance and ServiceProficiency

The instruction book contains directions on how tocarry out the most common service and maintenancetasks safely and correctly. Read them carefully beforestarting work.

Literature for more major tasks is available from yourVolvo Penta dealer.

Never do a job if you are not entirely sure about howto do it. Please contact your Volvo Penta dealer andask for assistance instead.

Stop the Engine

Stop the engine before opening or removing the en-gine hatch/hood. Maintenance and service should bedone with the engine stopped, unless otherwise speci-fied.

Prevent the engine from being started by pulling outthe starter key and cutting the current with the mainswitch. Lock them in the off position. Fix a notice bythe operator’s station to say that work is in progress.

Working with, or approaching a running engine is asafety risk. Hair, fingers, loose clothes, or droppedtools can catch on rotating components and cause se-vere injury. Volvo Penta recommends that all servicework which requires the engine to be running shouldbe done by an authorized Volvo Penta workshop.

Safety information

4

Removing the Engine

When removing the engine the lifting rings mounted onthe engine should be used. Always check that the lift-ing devices are in good condition and that they havethe correct capacity for the lift (engine weight togetherwith auxiliaries, if fitted). The engine should be raisedwith an adjustable lifting boom for safe handling. Allchains or cables should be parallel to each other andshould be as square as possible to the top of the en-gine. Note that auxiliary equipment installed on the en-gine may change its center of gravity. Special liftingdevices may then be needed to obtain a correct bal-ance for safe handling. Never carry out work on an en-gine that is only suspended in a hoist.

Before Starting

Re-install all guards which have been removed duringservice work, before re-starting the engine. Make surethat there are no tools or other objects left behind onthe engine.

Never start a turbocharged engine without the air filterin place. The rotating compressor turbine in the turbo-charger can cause severe injury. There is also a riskthat foreign bodies could be sucked in and cause ma-chinery damage.

Fire and ExplosionFuel and Lubricating Oil

All fuel, most lubricants and many chemicals areflammable. Always read and follow the directions onthe packages.

Work on the fuel system must be done with the en-gine cold. Fuel leakages and spills on hot surfaces orelectrical components can cause fires.

Store oil and fuel-soaked rags and other flammablematerial in such a way that there is no danger of themcausing fire. In certain circumstances oil-soaked ragscan spontaneously ignite.

Never smoke when filling fuel, lubricating oil or whenin the vicinity of fueling stations or the engine bay.

Non-original Spare Parts

Components in fuel systems and electrical systemson Volvo Penta engines are designed and manufac-tured to minimize the risk of explosions and fire, in ac-cordance with applicable legal requirements.

The use of non-original spare parts can cause an ex-plosion or fire.

Batteries

Batteries contain and give off oxyhydrogen, especiallywhen charged. This gas is very flammable and highlyexplosive.

Smoking, naked flames or sparks must never occur inthe vicinity of batteries or the battery compartment.

Incorrect connection of a battery cable or start cablecan cause a spark which can in turn be sufficient tocause the battery to explode.

Start Spray

Never use start spray or similar preparations as astart aid on engines with air pre-heating (glow plugs/starting heater). They may cause an explosion in theinlet manifold. Danger of personal injury.

Safety precautions for operation and maintenance (contd.)

Safety information

5

Hot Surfaces and FluidsA hot engine always presents the risk of burns. Be onyour guard against hot surfaces: the exhaust mani-fold, turbocharger, oil pan, charge air pipe, startingheater, hot coolant and hot lubricating oil in pipes,hoses etc.

ChemicalsMost chemicals, such as glycol, rust preventer, con-servation oils, degreasers etc. are hazardous. Alwaysread and follow the directions on the packages.

Certain chemicals such as preservative oils are flam-mable and also dangerous when inhaled. Ensure goodventilation and use a protective mask when spraying.Always read and follow the directions on the packages.

Keep chemicals and other hazardous materials out ofthe reach of children. Hand in surplus or used chemi-cals to a recycling station for disposal.

Lubrication SystemHot oil can cause burns. Avoid skin contact with hotoil. Make sure that the oil system is de-pressurizedbefore starting work. Never start or run the engine withthe oil filler cap removed, because of the risk of oilejection.

Cooling SystemAvoid opening the coolant filling cap when the engineis hot. Steam or hot coolant can spray out and causeburns.

Nevertheless, if the filler cap, coolant hose etc., hasto be opened or removed when the engine is hot, undothe filler cap slowly and carefully, to release the pres-sure before removing the filler cap completely andstarting work. Note that the coolant can still be hotand cause burns.

Fuel SystemAlways protect your hands when searching for leaks.Fluids which leak under pressure can force their wayinto body tissue and cause severe injury. There is arisk of blood poisoning (septicemia).

Always cover the alternator if it is located beneath thefuel filters. Fuel spillage can damage the alternator.

Electrical systemCut the Current

Before any work is done on the electrical system, theengine must be stopped and the current cut by switch-ing off the main switch(es). External current supply forengine heaters, battery chargers or other auxiliaryequipment connected to the engine must be discon-nected.

Batteries

Batteries contain a highly corrosive electrolyte. Pro-tect your eyes, skin and clothes when handling orcharging batteries. Always use protective goggles andgloves.

If acid comes into contact with your skin, wash withsoap and plenty of water. If you get battery acid inyour eyes, flush at once with lots of cold water, andseek medical assistance immediately.

Arc WeldingRemove the positive and negative cables from thebatteries. Then disconnect all cables connected to thealternator.

Always connect the welder earth clamp to the compo-nent to be welded, and as close as possible to theweld site. The clamp must never be connected to theengine or in such a way that current can pass througha bearing.

When welding is completed: Always connect the al-ternator cables before the battery cables are re-at-tached.

6

IntroductionThis instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta industrialengine. It contains the information you need to be able to operate and maintain the engine in a safe and proppermanner. Read the instruction book carefully and learn how to operate the engine, controls and other equipment ina safe manner before you start the engine.

Environmental careAll of us want to live in a clean, healthy environment,where we can breathe clean air, see healthy trees,have clean water in lakes and seas, and be able toenjoy sunshine without fearing for our health. Unfortu-nately, this cannot be taken for granted these days; itis something all of us must work toward.

As an engine manufacturer, Volvo Penta has particularresponsibility and for this reason, environmental care isan obvious foundation of our product development. Vol-vo Penta currently has a broad range of engines wheregreat progress has been made in the reduction of em-misions, fuel-consumption and engine noise etc.

We hope that you will take care to maintain thesequalities. Always follow the directions in the instruc-tion book regarding fuel grades, operation and mainte-nance, to avoid unnecessary environmental impact.Please contact your Volvo Penta dealer if you noticeany changes such as increased fuel consumption orincreased exhaust smoke.

Always remember to hand in hazardous waste suchas drained oil, coolant, old batteries etc. for disposalat a recycling facility.

Through our common efforts, we can together make avaluable contribution to the environment.

Running inThe engine must be “run in” during its first 10running hours, in accordance with the following:

Use the engine in normal operation. Full load shouldonly be applied for short periods. Never run the engineat constant revolutions for prolonged periods duringrunning in.

Higher oil consumption is normal during the first 100-200 hours of operation. For this reason, check the oillevel more frequently than the normal reccomendation.

When an disengageable clutch is installed, this shouldbe checked more carefully during the first days. Ad-justments may need to be done to compensate bed-ding-in of the friction plates.

Fuel and OilsOnly use the grades of fuels and oils recommended inthe instruction book (refer to the “Maintenance” chapterunder the fuel and lubrication system headings). Othergrades of fuel and oils can cause malfunctions, increasedfuel consumption and over time even shorten the life ofthe engine.

Always change the oil, oil filter and fuel filter accordingto the prescribed intervals.

Maintenance and Spare PartsVolvo Penta engines are designed for maximum reli-ability and long life. They are built to withstand a de-manding environment, but also to have the smallestpossible environmental impact. Regular maintenanceand the use of Volvo Penta original spare parts willensure these qualities are retained.

Volvo Penta has a world-wide network of authorizeddealers. They are Volvo Penta product specialists,and have the accessories, original spares, test equip-ment and special tools necessary for high quality ser-vice and repair work.

Always comply with the maintenance schedule inthe instruction book, and remember to note theengine/transmission identification number whenyou order service and spare parts.

IMPORTANT! This instruction book describes the engine and equipment as offered for sale by Volvo Penta.Variations in appearance and function of the controls and instruments may occur in certain variants. In thesecases, refer to the operator’s manual for the relevant application.

Introduction

7

Certified EnginesIf you own an emission certified engine, which isused in an area where exhaust emissions are regu-lated by law, it is important to be aware of the fol-lowing:

Certification means that an engine type has beenchecked and approved by the relevant authority. Theengine manufacturer guarantees that all engines madeof the same type are equivalent to the certified engine.

This places special demands on the maintenanceand service you provide your engine; accordingly:

• Maintenance and service intervals recommendedby Volvo Penta must be complied with.

• Only Volvo Penta original spare parts may beused.

• Service to injection pumps, pump settings and in-jectors must always be done by an authorizedVolvo Penta workshop.

• The engine must not be converted or modified, ex-cept with accessories and service kits whichVolvo Penta has developed for the engine.

• No installation changes to the exhaust pipe andengine air inlet ducts may be made.

• Any seals on the engine may not be broken by un-authorized persons.

Otherwise the general instructions in the Operator’sManual regarding operation, maintenance and serviceapply.

IMPORTANT! Neglected or inferior maintenance/service or the use of non-original spare parts, willresult in AB Volvo Penta no longer acceptingresponsibity for engine conformity with the certi-fied model.

Damage, injury and/or costs which arise fromthis will not be compensated by Volvo Penta.

WarrantyYour new Volvo Penta industrial engine is covered by a limited warranty, according to the terms andconditions set out in the Warranty and Service book.

Please note that AB Volvo Penta’s liability is limited to that which is stated in the Warranty and Servicebook. Read it carefully, as soon as possible after delivery. It contains important information about,among other things, warranty cards, sevice intervals and maintenance which, as the owner, is your re-sponsibility to know, check and execute. Otherwise AB Volvo Penta may fully or partly refuse to honorits warranty undertakings.

Please contact your Volvo Penta dealer if you have not received a Warranty and Service book, ora customer copy of the warranty card.

8

PresentationTAD734GE is a direct injection, straight, 6-cylinder engine.

The engine is equipped with a “common rail” fuel injection system, IEGR (Internal Exhaust Gas Recirculation),electronically-controlled fuel management (EMS 2), turbocharger, thermostatically-controlled cooling systems andelectronic speed control.

Technical DescriptionEngine and Cylinder Block

– The cylinder block and cylinder head are manufac-tured of alloyed cast iron

– Seven bearing induction-hardened crankshaft

– Replaceable wet cylinder liners

– Cast aluminum pistons with oil cooling

– Three piston rings, with a “keystone” type top ring

– Induction-hardened overhead camshaft with valvelifters 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 (Engine Management System). See sepa-rate description.

Lubrication System

– Water oil cooler

– Crankshaft driven lubrication oil pump

– Full flow filter with bypass

Turbocharging System

– Turbo compressor

Cooling System

– Radiator with expansion tank

– Air-cooled charge air cooler

Electrical system

– 24 V

Presentation

9

Identification Numbers

1. Engine model2. Engine specification number3. Engine series number (10 digits)4. Engine power, peak, without fan5. Engine rpm6. Engine code (linked to EPA/EU Tier III approval)

7. Rated power, standard(peak power according to Tier III)

8. Air temperature in °C (°F), in accordancewith ISO 3046

9. Altitude above mean sea level, in accordancewith 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 andthe other on top of the valve cover.

Engine Plate

Presentation

10

Component Locations, TAD734GE

1. Crankcase ventilation, (sealed crank-case ventilation optional)

2. Oil Filler

3. Fuel filter

4. Common Rail unit, with safety valveand rail pressure sensor

5. Oil filter

6. Lifting eyes, (2 pcs)

7. Inlet, after charge-air cooler

8. Coolant 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, to cooler

29. Oil pipe, from turbo

30. Turbo

31. Relay

32. Exhaust manifold

Presentation

11

Location of sensors

1. Proportional solenoid valve, high pres-sure pump – fuel (MPROP)

2. Coolant 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.

Presentation

12

EMS 2EMS 2 (Engine Management System) is an electronic system with CAN communication (Controller Area Network)for diesel engine control. The system has been developed by Volvo and includes fuel control and a diagnosticfunction.

Fuel Management

The engine fuel requirement is analyzed up to 100times per second. The amount of fuel injected into theengine and the injection timing are fully electronicallycontrolled, via fuel valves on the unit injectors.

This means that the engine always receives the cor-rect amount of fuel in all operating conditions, whichprovides lower fuel consumption and minimal exhaustemissions etc.

Diagnostic Function

The task of the diagnostic function is to discover andlocalize any malfunctions in the EMS 2 system, toprotect the engine and to inform about any problemsthat occur.

If a malfunction is detected it is denoted by warninglamps, a flashing diagnostic lamp or in text on the in-strument panel, depending on the equipment used. Ifa flashing or text fault code is generated, use thecode for guidance when trouble shooting. Fault codescan also be deciphered by Volvo’s VODIA tool at au-thorized Volvo Penta workshops.

If there is a serious malfunction, the engine will beshut down altogether, or the control unit will reduceavailable power (depending on the application). Onceagain, a fault code will be generated for guidance introuble shooting.

Summary

The system comprises, among other things, of a con-trol unit, sensors and injectors. The sensors send in-put signals to the control unit, which in turn controlsthe injectors.

The information from the sensors give exact dataabout prevailing operating conditions and allows theprocessor in the control module to calculate correctinjection amount, injection timing and check enginehealth.

Input signals

The control unit receives input signals about engineoperating conditions from the following components:

– coolant temperature sensor

– charge air pressure and temperature sensor

– rpm sensor, camshaft

– rpm sensor, flywheel

– coolant level sensor

– oil pressure sensor

– fuel pressure sensor

– water in fuel indicator

– fuel pressure in distributor manifold

Output signals

Based on the input signals the control module controlsthe following components:

– unit injectors

– starter motor

– main relay

– pre-heating relay

– FCU (Fuel Control Unit)

Presentation

13

Instrument, EMS 2NOTE! All instruments are fittings.

CIU – Control Interface UnitThe CIU is the “translator” between the EMS 2 enginecontrol unit and the customer’s own control panel. TheCIU has two serial communication links, one fast andone slow.

The fast one is a so-called CAN link. All data relatedto instruments, indication lamps, connectors and po-tentiometers is controlled by this link.

The slow link manages diagnostic information forflashing codes etc.

Easy Link instrument(only in conjunction with CIU or DCU)The following “Easy Link” 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 UnitThe DU is an instrument panel which shows engineworking values graphically on an LCD screen. It con-sists of an computerised unit for permanent installa-tion in a control panel.

The DU is connected between the engine control unitand the CIU or DCU.

Monitoring

– Engine rpm, charge pressure, charge temperature,coolant temperature, oil pressure, oil temperature,fuel pressure, engine hours, battery voltage, mo-mentary fuel consumption and average fuel con-sumption (trip fuel)

Diagnostics

– Shows active fault codes in text

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DCU (Display Control Unit)The DCU (Diesel Control System) control panel is available as an accessory for the EMS (Engine ManagementSystem) electronic control system. The DCU is a digital instrument panel which communicates with the enginecontrol unit. The DCU has a number of functions such as engine control, engine monitoring, diagnostics and pa-rameter setting.

The menus in the DCU system can be used to check, and in some cases to set, a number of different functionsin 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. Selects from menus

9. Scrolls up in menus

10. ESC. Return to previous menu selection

1 2 3 4 5

7

8910

6

StartWhen the DCU panel is started, the “Engine Data” menu is displayed; press “ESC” to come to the main menu.

15

MenusThere are several sub-menus under each main menu.There is not always space for all the menu choices onthe display. To scroll through the menus, use the “7”and “9” buttons on the display. Press the “SEL” button“8” to make a selection. See illustration on the previ-ous page.

NOTE! The “Setup” menu can be used to select thelanguage that you want to use on the display.

Main menu� Engine data, current engine data

� Preheat, manual activation of preheatingOBS! Must be activated when the temperature isbelow 0°.

� Governor mode, activates droop

� Diagnostics, shows fault codes in text

� Trip reset, restores trip data

� Setup, parameter setting

� Information, shows the data for the applicablehardware, software, data set and engine identifica-tion of the engine and DCU

Engine datashows relevant engine data.

• Engine rpm, can be controlled with the “SPEED +”and “SPEED -” buttons (rpm)

• Charge pressure (kPa)

• Coolant temperature (°C)

• Charge air temperature (°C)

• Oil pressure (kPa)

• Oil temperature (value not shown – sender missing)

• Engine hours (h)

• Battery voltage (V)

• Fuel consumption (l/h)

• Momentary fuel consumption (trip fuel) (l)

16

Preheatmanual activation of preheating. When activated, theEMS system senses at start if preheating is neces-sary. For automatic preheating, refer to “Setup”/“Pre-heat on ignition” menu.

NOTE! Must be activated when the temperature is be-low 0°.

The preheating time is adjusted to suit the enginetemperature, and can last for up to 50 seconds bothbefore and after starting. Also refer to “Starting proce-dure, EMS 2”.

• Press “SEL”, the text “Preheat requested” is dis-played.

• The display automatically returns to the “EngineData” menu.

Governor modeactivates/deactivates droop. To set the droop level,refer to the “Setup”/“Governor gradient” or “Govenordroop”.

• Select “Isochronous mode” or “Droop mode” withthe SEL button.

Diagnosticsshows the error list containing the 10 latest active andinactive faults. The fault codes are shown as text onthe display.

• Scroll through the error list with the arrow keys.

Trip resetresets trip data e.g. fuel consumption.

• Press the SEL button to reset trip data.

17

Setupparameter setting in the engine’s control systems. De-pending on whether you select “Versatile” or “Genset”from “Set application”, different menus will appear un-der “Customer parameter”; see below.

The parameters which can be set/selected (choice ismade with the SEL button) are:

• Set application, setting of “Versatile” or “Genset”.Depending on what is chosen here, differentmenus will appear under “Customer parameter”,

• Unit, selection of units of measurement (metric orUS units)

• Language, selection of the language shown in thedisplay. You can choose between English, French,German and Spanish.

• Stop energized to, setting of external stop input.Activated by “Stop” or “Run”.“Stop”: The 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 andvoltage limits. See “Throttle input setting”.

• Display setting, display settings. See “Displaysetting”.

Customer parameter/Versatile

• Idle engine speed – setting idle rpm

• Preheat on ignition – activation of automatic pre-heat. The engine control system senses if pre-heating is needed and activates it directly whenswitched on.

• Governor gradiant (Nm/rpm) – setting the drooplevel, when this has been activated. Refer to“Governor droop” in the main menu for activation.

• Oil temp warning limit (°C) – setting oil tempera-ture alarm limit.

• Coolant temp warning limit (°C) – settingcoolantt temperature alarm limit.

18

Customer parameter/Genset

• Primary engine speed – selection of engine rpm,1500 or 1800 rpm.

• Preheat on ignition – activation of automatic pre-heat. The engine control system senses if pre-heating is needed and activates it directly whenswitched on.

• Governor droop (%) – setting the droop level,when this has been activated. Refer to “Governordroop” in the main menu for activation.

• Overspeed limit (%) – setting the speed for theexcess rpm alarm, % of set engine rpm.

• Overspeed shutdown – activates engine stop atexcess rpm alarm. Refer to “Overspeed limit” toactivate 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 settingrpm control setting (throttle operation).

• Set throttle mode –“OFF” – rpm is controlled via the DCU panel.“ext throttle input” – rpm is regulated by potenti-ometer (gaspedal).“ext voltage input” – rpm is regulated by an exter-nal control unit.

• Set idle voltage (V) – setting voltage level at idle.

• Set max voltage (V) – setting voltage level atmaximum rpm.

0

100

Idle MaxVoltage (V)

Potentiometervalue (%)

0

100

Max IdleVoltage (V)

Potentiometervalue (%)

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Display settingsettings for the display. Adjustment is made with the“7” and “9” buttons; see DCU panel illustration.

• Set contrast (%) – contrast setting.

• Set backlight time (sec) – sets the time (in sec-onds) for the display backlight; the backlightswitches off when the panel is not in use.

• Set backlight brightness – sets backlight bright-ness.

Informationdisplays engine and DCU data.

• Engine hardware Id – engine control unit articlenumber

• Engine software Id – engine control unit softwarearticle number

• Engine dataset1 Id – article number, enginedataset 1.

• Engine dataset2 Id – article number, enginedataset 2.

• Vechicle Id – chassis number

• DCU hardware Id – DCU article number.

• DCU software Id – DCU software article number.

• DCU dataset1 Id – article number, DCU dataset 1.

• DCU dataset2 Id – article number, DCU dataset 2.

20

Starting the engineMake it a habit to check the engine and engine room before starting. This will help you to discover quickly if anythingabnormal has happened, or is about to happen. Also check that instruments show normal values after starting.

Before Starting

• Check that the oil level is between the MAX andMIN marks. Refer to the “Maintenance, lubricationsystem” chapter.

• Open the fuel cocks.

• Check that there is no evidence of oil, fuel or cool-ant leaks present.

• Check the air filter pressure-drop indicator. Refer tothe “Maintenance, Engine, General” chapter:

• Check the coolant level and that the radiator is notblocked externally. Refer to the “Maintenance,cooling system” chapter:

WARNING! Do not open the expansion tank capwhen the engine is hot. Steam or hot fluid couldspray out.

• Turn the main current on.

IMPORTANT! Never break the circuit with themain switch(es) when the engine is running. Thiscan damage the alternator.

• Move the engine speed control to idle, and openthe disengageable clutch/gearbox if installed.

Starting the engine

21

Start routine (DCU)The preheating time is adjusted to suit the enginetemperature, and can continue for up to 50 secondsboth before and after starting.

The starter motor connection time is maximized to 30seconds. After that, the starter motor circuit is cut for80 seconds to protect the starter motor against over-heating.

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 mainmenu.

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 the“START” button (2).

Without preheating

1. Pess the “ON/OFF” button (6).

2. Press the “START” button (2).

Warm through the engine at idle (1500/1800 rpm).

2

6

7

9

Starting the engine

22

Starting in extreme coldTo facilitate – and in some cases enable – enginestarting, certain preparations must be made:

Use a winter grade fuel (of a well-known make) whichis approved for the prevailing temperature. This reduc-es the risk of wax deposits in the fuel system. At ex-tremely low temperatures, the use of a fuel heater isrecommended.

For fully acceptable lubrication, a synthetic engine oilof recommended viscosity for the prevailing tempera-ture should be used. Refer to the “Maintenance, lubri-cation system” chapter. Synthetic lubricants withstandwider temperature ranges than mineral-based lubri-cants.

Preheat the coolant with a separately installed electricengine heater. In extreme cases, a diesel-burning en-gine heater may be needed. Ask your Volvo Pentadealer for advice.

IMPORTANT! Make sure that the cooling sys-tem is filled with a glycol mixture. Refer to the“Maintenance, cooling system” chapter.

The batteries must be in good condition. Cold weatherreduces battery capacity. Increased battery capacitymay be necessary.

Starting the engine

23

Never use start spray

WARNING! Never use start spray or similar prod-ucts as a starting aid. They may cause an explo-sion in the inlet manifold. Injury may also result.

Starting with auxiliary batteries

WARNING! Batteries (especially auxiliary batter-ies) contain oxyhydrogen which is highly explo-sive in contact with air. A spark, which can beformed if the auxiliary batteries are wrongly con-nected, is enough to make a battery explode andcause damage.

1. Check that the auxiliary 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. Thenconnect the black (-) jumper cable to the auxilliarybattery and finally to a place a short distancefrom the discharged batteries e.g. the mainswitch negative cable or the negative cable’s startmotor connector.

3. Start the engine.

WARNING! Do not disturb the connections dur-ing the start attempt (risk of arcing), and do notstand leaning over any of the batteries.

4. Disconnect the jumper cables in reverse order.

WARNING! The permanent standard batterycables must absolutely not be disconnected.

24

OperationCorrect operating technique is very important for both fuel economy and engine life. Always let the engine warmup to normal operating temperature before full power is demanded. Avoid sudden throttle openings and operationat high engine rpm.

Check instrumentsCheck all instruments immediately after starting, andthen regularly during operation.

IMPORTANT! On engines in continuous opera-tion, the lubricating oil level must be checked, atleast every 24 hours. Refer to the “Maintenance,lubrication system” chapter.

Fault indicationIf the EMS 2 system receives abnormal signals fromthe engine, the control unit generates fault codes andsignals alarms by means of lamps and audible warn-ings. This is done by means of CAN signals to the in-strument.

More information about fault codes and trouble shoot-ing is found in the “Diagnostic function” chapter.

Operation at low loadAvoid long-term operation at idle or at low load, sincethis can lead to increased oil consumption and even-tually to oil leakage from the exhaust manifold, sinceat low turbo pressures oil will seep past the turbo-charger seals and carry over with the charge air intothe inlet manifold.

As a consequence of this carbon builds up on valvesand piston crowns, and in exhaust ports and the ex-haust turbine.

At low loads the combustion temperature becomes solow that complete combustion cannot be guaranteed,with the consequent possibilities of fuel-dilution of thelubricating oil, and over time, leakage from the ex-haust manifold.

If the following points are carried out as a comple-ment to normal maintenance, there will be no riskof malfunctions caused by operation at low load:

• Reduce operation at low load to a minimum. If theengine is regularly test run without load once aweek, the duration should be limited to 5 minutes.

• Run the engine at full load for about 4 hours oncea year. Carbon deposits in the engine and exhaustsystem are thus given the opportunity of beingburned up.

25

Engine shutdownDuring longer shutdown periods, the engine must be run and warmed through at least once every 2 weeks. Thisprevents corrosion in the engine. If the engine is expected to remain unused for two months or more, preservationmust be carried out: Ses the chapter “Shutdown”.

IMPORTANT! If there is a risk of frost, the coolant in the cooling system must have sufficient frost protec-tion. Refer to the “Maintenance, cooling system” chapter. A poorly charged battery can freeze and burst.

Before stoppingLet the engine run for a few minutes without load be-fore stopping. In this manner temperatures are evenedout and hotspots are avoided while at the same timethe turbocharger cools a little. This will contribute tolong 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 forsigns of leakages.

• Turn off the main switches during longer stop-pages.

• Carry out service in accordance with the mainte-nance schedule.

Auxiliary StopThe auxiliary stop (AUX STOP) is located on the leftside of the engine, to the right of the control unit.NOTE! The auxiliary stop may under no circum-stances, be used as the “normal” stop.

WARNING! Approaching or working on a runningengine is a safety risk. Watch out for rotatingcomponents and hot surfaces.

26

MAINTENANCE SCHEDULEWARNING! Before starting maintenance work, read the “Maintenance” chapter care-fully. It contains instructions on how to carry out the work safely and correctly.

IMPORTANT! When both running hours and calendar periods are specified, carry outthe maintenance item at whichever time is reached first. Maintenance items marked

must be carried out by an authorized Volvo Penta workshop.

Daily, before first start

• Engine oil, level check 1) .............................................................................. page. 31

• Coolant, level check ......................................................................................page 35

• Radiator, external check and cleaning ............................................................page 36

• Leakage check, engine .............................................................................. not shown1) In continuous operation, checks should be made 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 321) 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, check electrolyte level ......................................................................page 42

Every 6 months

• Coolant filter, change 1) .............................................................................. not shown1) However, the filter need not be changed when coolant is changed

Maintenance schedule

GeneralFor maximum reliability and service life to be achieved, it is important that the engine receives regular mainte-nance. By following maintenance recommendations, engine quality is kept high and unnecessary environmentalimpact avoided.

27

Maintenance schedule

Every 125-500 running hours or at least every 12 months

• Engine oil and oil filter, change 1) 2) .................................................................page 321) 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.


• Fuel tank (sludge trap), drain. .................................................................... Not shown

• Drive belts, inspection/adjustment .................................................................page 29


• Charge air pipe, leakage check. .....................................................................page 28

• Fuel filters, replacing ......................................................................................page 40


Valve clearance, inspection/adjustment ..................................................... not shown

Every 2000 hours or every 12 months

• Inspection, air compressor, change. .......................................................... not shown

• Air filter, cleaning1) ..................................................................................... not shown1) When operating in extremely dirty conditions, cleaning must take place often.


Turbocharger, check .................................................................................. not shown

Engine with equipment, general check ....................................................... not shown


Injector, check ........................................................................................... not shown

Every 5000 running hours or at least every 24 months

• Coolant, changing ................................................................................... pages 35-36

28

Maintenance

This chapter describes how the prescribed maintenance items must be carried out. Read the instructions carefullybefore starting work. The times when maintenance items are to be carried out are set out in the previous chapter:Maintenance schedule.

WARNING! Read through the safety precautions for maintenance and service in the “Safety information”chapter before starting work.

WARNING! Maintenance and service should be performed with the engine stopped unless otherwise speci-fied. Immobilize the engine by removing the ignition key and turning of the power supply at the main switch.Approaching or working on a running engine is a safety risk. Watch out for rotating components and hot sur-faces.

Engine, general

General inspectionMake it a habit to inspect the engine and engine com-partment visually before engine start and after oper-ations when the engine is stopped. This will helpyou 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 drivebelts, loose connections, damaged hoses and electri-cal cables. This inspection only takes a few minutesand can prevent serious malfunctions and expensiverepairs.

WARNING! Deposits of fuel, oils and grease onthe engine or in the engine compartment are afire hazard and must be removed as soon asthey are discovered.

IMPORTANT! If you discover a leakage of oil,fuel or coolant, investigate the cause and fix thefault before you start the engine.

IMPORTANT! Pay attention to the followingwhen washing with a power washer: Never aimthe water jet at radiators, charge air cooler,seals, rubber hoses or electrical components.

Charge air pipe, leakage checkInspect the condition of the charge air pipes, hoseunions and the condition of the clamps with regard tocracks and other damage. Change as necessary.

29

Maintenance

Drive belt, inspection/changingInspection should be done after running, when thebelts are hot.

It should be possible to press the alternator belts anddrive belts down about 3-4 mm between the pulleys.

The alternator belts and drive belts have automaticbelt tensioners and do not need to be adjusted. Checkthe condition of the belts. Change as necessary; referto “Alternator belt, change” and “Drive belt, change”.

1. Release the belt tensioner and lock it in placewith 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 beltsare correctly aligned in their grooves and are cor-rectly tensioned.

Maintenance

30

Oil change intervals vary from 125 to 500 hours depending on oil grade and sulfur content of the fuel. Note thatoil change intervals must never exceed a period of 12 months.

If you want longer oil change intervals than given in the table below, the condition of the oil must be checked bythe oil manufacturers through regular oil testing.

NOTE! The oil filters must be changed during each oil change.

NOTE! Mineral based oil, as well as fully or semi-synthetic, can be used on condition that it complies with thequality requirements 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 marketsoutside Europe (instead of ACEA E3).

VDS = Volvo Drain SpecificationACEA = Association des Constructeurs Européenne d’AutomobilesAPI = American Petroleum InstituteTBN = Total Base Number

Lubrication System

Sulfur percentage in fuel by weight

Oil grade < 0,5 % 0,5-1,0 % > 1,0 %1)

Oil change interval: reached first in operation

open crankcase VDS-3 500 hrs/12 mos. 250 hrs/12 mos. 125 hrs/12 mos.ventilation VDS-2

ACEA: E7, E5, E3API: CI-4, CH-4, CG-4

closed crankcase ACEA:E6, E4 500 hrs/12 mos. 250 hrs/12 mos. 125 hrs/12 mos.ventilation API: CI-4, CH-4

NOTE! Fully synthetic oil must be used

31

Maintenance

Oil level. InspectionMake sure that the oil level is between the MIN andMAX marks.

IMPORTANT! In continuous operation, the oillevel should be checked every 24 hours.

WARNING! Approaching or working on a runningengine is a safety risk. Watch out for rotatingcomponents and hot surfaces.

ViscositySelect the viscosity from the adjacent table, for the ap-propriate continuous ambient air temperature.

*Denotes synthetic or semi-synthetic oils

Oil change volumeRefer to the “Technical Data” chapter

Maintenance

32

Engine oil. ChangeAlways follow the recommended oil change intervaland always change the oil filter during oil changes. Onstatic engines the drain plug must not be removed.Use an oil change pump to remove the oil.

WARNING! Hot oil and hot surfaces can causeburns.

1. Run engine until warm.

2. Remove the drain plug. Drain the oil.

NOTE! Collect the old oil and old filters and handthem to a re-cycling station for disposal

3. Install the drain plug with a new gasket

4. Change the oil filter according to the “Oil filter,changing” instruction.

6. Fill oil to the correct level.

NOTE! Do not fill over the MAX level.

7. Start the engine and let it idle. Check that the oilpressure is normal.

8. Stop the engine. Check that no oil leakageoccurs around the filters. Top up with oil as nec-essary.

Oil filter. ChangeChange the oil filters during each oil change.

WARNING! Hot oil and hot surfaces can causeburns.

1. Drain the oil according to the instructions in “En-gine oil Replacement”.

NOTE! Position a suitable vessel underneath the filterto avoid oil spillage.

2. Clean around the oil filter.

3. Carefully remove the filter cover, (1) with filter.

4. Remove the O-ring (2) and filter (3).

5. Let the oil drip off, into a collection vessel.

6. Install a new filter (3) and a new O-ring (2).

7. Install the filter cover with filter (1).(Tighten to 25 Nm.)

8. Top up with oil accoirding to the instruction in “En-gine oil. Change”.

33

Maintenance

Cooling System

The cooling system ensures that the engine works at the right temperature. It is a closed system and musttherefore always be filled with a mixture of at least 40 % concentrated coolant and 60 % water, to protect againstinterior corrosion, cavitation and frost bursting.

We recommend that you use “Volvo Penta Coolant, Ready Mixed”, alternatively “Volvo Penta Coolant” (con-centrated) mixed with pure water according to spec, see “Coolant. Mixing”. This grade of coolant is the only onesuitable for, and approved by, Volvo Penta.

For complete engine protection the coolant should contain good quality ethylene glycol of a suitable chemicalcomposition. Using an anti-corrosion mixture exclusively is not permitted in Volvo Penta engines. Never use wateralone as the coolant.

IMPORTANT! Coolant of a suitable chemical composition must be used all year round. This applies even ifthere 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 usedor if the instructions concerning coolant mixing have not been adhered to.

NOTE! Corrosion protection additives become less effective after a time, which means that the coolant must bereplaced; see “Maintenance schedule”. The cooling system should be flushed when the coolant is changed; referto “Cooling system. Cleaning”.

“Volvo Penta Coolant” is a concentrated coolantwhich must be mixed with water. It has been preparedto work best with Volvo Penta engines and offers ex-cellent protection against frost and cavitation damage,plus frost bursting.

“Volvo Penta Coolant, Ready Mixed” is a ready-mixed coolant, 40 % “Volvo Penta Coolant” and 60 %water. This mixture protects the engine from corrosiondamage, cavitation damage and frost bursting down to-28 °C.

Maintenance

34

Coolant. MixingWARNING! All glycol is dangerous to humanhealth and ecologically damaging. Must not beingested! Glycol is flammable.

IMPORTANT! Ethylene glycol should not bemixed with other types of glycol.

Mix: 40 % “Volvo Penta Coolant” (conc. coolant) 60 % vatten

This mixture protects against internal corrosion, cavi-tation and frost damage down to -28 °C. (Using 60 %glycol lowers the freezing point to -54 °C.) Never mixmore than 60 % concentrate (Volvo Penta Coolant) inthe cooling liquid, since this would give reduced cool-ing effect and increase the risk of overheating andfrost damage.

IMPORTANT! The coolant must be mixed withpure water, use distilled, de-ionized water.The water must fulfill the requirements specifiedby Volvo Penta, see “Water quality”.

IMPORTANT! It is extremely important that thecorrect concentration of coolant is added to thesystem. Mix in a separate clean vessel beforefilling the cooling system. Make sure that the liq-uids mix.

Water quality

ASTM D4985:

Total solid particles ....................................... < 340 ppm

Total hardness .............................................. < 9.5° dH

Chloride ......................................................... < 40 ppm

Sulfate ........................................................... < 100 ppm

pH value ........................................................ 5.5-9

Silica (acc. to ASTM D859) .......................... < 20 mg SiO2/l

Iron (acc. to ASTM D1068) .......................... < 0.10 ppm

Manganese (acc. to ASTM D858) ............... < 0.05 ppm

Conductivity (acc. to ASTM D1125) ............ < 500 µS/cm

Organic content, CODMn (acc. ISO8467) .... < 15 mg KMnO4/l

35

Maintenance

Coolant. Checking and fillingWARNING! Do not open the filler cap when theengine is hot, except in emergencies. Steam orhot fluid could spray out.

Check the coolant level daily before starting. Top thecoolant up as necessary.

The level should be about 50 mm below the sealingplane of the filler cap, or between the MIN and MAXmarkings, if a separate expansion tank is installed.

IMPORTANT! Topping up should be done withthe same type of mixture as is already in thecooling system; refer to “Coolant, mixing”.

Filling a completely empty systemFilling should be done with the engine stopped. Fill upslowly, to allow the air to flow out. The system isvented automatically.

Fill up with coolant to the correct level. Do not startthe engine until the system is vented and com-pletely filled.

Start the engine and warm it up until the thermostatsare open, about 20 minutes. Open any venting tapssome while after starting, to allow trapped air to es-cape. Check the coolant level and top up as neces-sary.

NOTE! If a heating unit is connected to the enginecooling system, the heat control valve should beopened and the installation vented during filling.

Maintenance

36

Coolant. DrainingBefore draining, stop the engine and unscrew thefiller cap.

WARNING! Do not open the filler cap when theengine is hot, except in emergencies. Steam orhot fluid could spray out.

WARNING! Glycol is poisonous (dangerous toingest). Collect the old coolant and hand it to are-cycling station for disposal.

1. Position a suitable vessel underneath the drainplug (1) and undo the plug.

2. Let the coolant run out.

IMPORTANT! Deposits, which must be clearedaway, 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. ExternalcleaningRemove guards as necessary, to access the radiator.

Clean with water and a mild detergent. Use a soft brush.Be careful not to damage the radiator matrix. Re-installthe components

IMPORTANT! Do not use a high-pressure powerwasher.

37

Maintenance

Cooling system, cleaningCooling performance is reduced by deposits in the ra-diator and cooling galleries. The cooling systemshould therefore be cleaned when coolant is changed.

IMPORTANT! Cleaning must not be done if thereis any risk of the cooling system freezing, sincethe cleaning solution does not have any frostprotection properties.

1. Empty the cooling system. Refer to “Cooling sys-tem, draining”.

2. Put a hose into the expansion tank filling hole andflush with clean water, according to Volvo Pentaspecifications – refer to section “Water quality” –until the water draining out is completely clear.

3. Should contamination still remain after a long pe-riod of flushing, cleaning using coolant may becarried out. Otherwise, continue according to item8 below.

4. Fill the cooling system with 15-20 % mixture ofconcentrated coolant. Use only Volvo Penta rec-ommended concentrated coolant mixed with cleanwater.

5. Drain the coolant after 1-2 days of operation.

NOTE! To prevent suspended material from settlingback in the system, emptying should be done rapidly,within 10 minutes, without the engine standing still fora long time. Remove the filler cap and if necessarythe lower radiator hose to increase emptying speed.

6. Flush the system immediately and thoroughly withclean hot water to prevent dirt from resettling onthe inner surfaces. Flush until the water that runsout is completely clean. Make sure that anyheater controls are set to full heating during emp-tying.

7. If contamination should still be left after a long pe-riod of flushing, cleaning may be carried out usingVolvo Penta radiator cleaner, followed up withVolvo Penta neutralizer. Follow the instructions onthe package carefully. Otherwise, continue ac-cording to item 8 below.

8. When the cooling system is completely free fromcontamination, close the drain taps and plugs.

9. Fill up with Volvo Penta recommended coolant,according to the instructions in the sections “Cool-ant, mixing” and “Coolant, filling”.

IMPORTANT! It is extremely important that thecorrect concentration and volume of coolant isadded to the system. Mix in a separate cleanvessel before filling the cooling system. Makesure that the liquids mix.

Maintenance

38

Fuel System

Use only recommended grades of fuel in accordance with the fuel specification below. Always observe the great-est cleanliness during re-fueling and work on the fuel system. Should dirt get into the system, it may cause injec-tor failure.

All work on the injection system of the engine must be done by an authorized workshop.

WARNING! Fire hazard. Work on the fuel system must be done with the engine cold. Fuel spills on hot sur-faces or electrical components can cause fires. Store fuel-soaked rags in such a way that they cannotcause a fire.

Fuel specification

At a minimum fuel must comply with national andinternational standards regarding marketable fuels.

NOTE! Bio-diesel according to EN 14214, kersoseneand light fuel oil may not be used.

The following fuel standards are approved:

EN590 (with nationally adapted environmental andcoldstandards)

ASTM-D975-No 1-D, 2-D

JIS KK 2204 (may only be used if lubricitycorresponds to EN 590)

Sulfur content: Conform to relevant national legisla-tion. If sulfercontent exceeds 0.5 percent by weightoil changeintervals must be ammemded; see head-ing “Lubrication system”.

Extremely low sulfur content fuel (urban diesel in Swe-den and city diesel in Finland) can cause a loss of upto 5 % of power and an increase in fuel consumptionof about 2-3 %.

39

Maintenance

Fuel pre-filter, draining water1. Stop the engine and open the fuel tap.

2. Position a suitable vessel underneath the filter.

3. Open the drain valve (1) and drain off fuel/water.

4. Unscrew the water reservoir from the filter car-tridge by turning it clockwise.

5. Clean the reservoir and screw it back onto the fil-ter cartridge.

6. Close the drain valve and open the fuel tap.

7. Vent the system. Test run the engine and checkthat no leakage occurs.

Fuel pre-filter, changeFilter inserts must be changed in accordance with themaintenance 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 cleanand that the seal is undamaged.Applya film of oil on the gasket.

5. Screw the filter cartridge and the water reservoirtogether and install them on the filter bracket

6. Open the fuel tap and vent the system.

7. Start the engine and check that no leakage oc-curs.

1

Maintenance

40

Purging the fuel systemThe fuel system must be vented after a filter change,if the fuel tank has been run dry, or after a long-termstoppage.

1. Position a suitable vessel underneath the fuel filter.

2. Open the vent screw (1).

3. Turn the hand pump anti-clockwise to open thepump.

4. Pump until the fuel is completely free from airbubbles.

4. Tighten the venting screw (1) and close the handfuel pump.

5. Start the engine and check that no leakage oc-curs.

1

Fuel filter, replace

NOTE! Do not fill the new fuel filter with fuel beforeassembly; there is a risk that contamination could getinto the system and cause malfunctions or damage.

WARNING! The fuel filter must be changed whenthe engine is cold, to avoid the risk of fire due tospilled 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 collection ves-sel.

3. Clean the filter mating surface on the filterbracket.

4. Lubricate the seal with diesel fuel and install thenew fuel filter. Tighten the fuel filter in accordancewith the instructions on the fuel filter.

5. If necessary, vent the fuel system; see “Fuel Sys-tem, Venting”.

41

Maintenance

WARNING! Before any work is done on the electrical system, the engine must be stopped and the currentcut by the main switch. Battery chargers or other auxiliary equipment installed on the engine must be discon-nected.

Electrical system

FusesTwo fuses are delivered with the engine wire harness.One 10 A to the EMS unit and one 150 A to the pre-heat element. No other fuses are delivered with theengine.

Fuses cut the current if the electrical system is over-loaded.

If the engine cannot be started or if the instrumentpanel stops working during operation, the fuse mayhave blown. Check and replace fuses or re-set circuitbreakers.

IMPORTANT! Always investigate the reason forthe overload!

Main switchThe main switch must never be switched off beforethe engine has been stopped. If the circuit betweenthe alternator and the battery is broken when the en-gine is running, the alternator can be damaged.

IMPORTANT! Never disconnect the current withthe main switch when the engine is running.

Electrical connectionsCheck that electrical connections are dry, free fromoxide and that they are securely tightened. Spraythese connections as necessary with water-repellentspray (Volvo Penta universal oil).

Maintenance

42

Battery. MaintenanceWARNING! Fire and explosion hazard. Batteriesmust never be exposed to naked flames orsparks.

WARNING! Never confuse the positive and neg-ative poles on the batteries. Risk of arcing andexplosion.

WARNING! Battery electrolyte is highly corro-sive. Always protect your eyes, skin and clotheswhen handling batteries. Always use protectivegoggles and gloves. If acid comes into contactwith your skin, wash with soap and plenty of wa-ter. If you get battery acid in your eyes, flush atonce with lots of water, and seek medical assis-tance immediately.

Connection and disconnectionWhen you connect batteries, first 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).

CleaningKeep the batteries dry and clean. Contamination andoxide on the batteries and battery posts can causestray currents, voltage drop and discharge, especiallyin wet weather. Clean oxidation from the battery postsand cable clamps with a brass brush. Tighten the ca-ble clamps securely and grease them with terminalgrease or petroleum jelly.

FillingThe electrolyte level should be 5-10mm above the cellplates in the battery. Add distilled water as needed.After filling, the battery should be charged for at least30 minutes by running the engine at fast idle. NOTE!Some maintenance-free batteries have special in-structions, which must be followed.

43

Maintenance

Batteries, chargingWARNING! Explosion risk! Hydrogen is given offwhen batteries are charged. This forms an explo-sive mixture with air. A short circuit, open flameor spark could cause a violent explosion. Venti-late well.

WARNING! Battery electrolyte is highly corro-sive. Protect your eyes, skin and clothes. Al-ways use protective goggles and gloves. If acidcomes into contact with your skin, wash withsoap and plenty of water. If you get battery acidin your eyes, flush at once with lots of cold wa-ter, and seek medical assistance immediately.

Charge batteries if they have become discharged. Ifthe engine is not used for a longer period of time, thebatteries should be fully charged, then trickle chargedif necessary (refer to the battery manufacturer’s rec-ommendations). Batteries are damaged by being leftdischarged, and can also freeze and burst more easilyin cold weather.

IMPORTANT! Follow the battery charger instruc-tion manual carefully. To avoid the risk of elec-trochemical corrosion when an external chargeris connected, the battery cables should be re-moved from the batteries before the charger isconnected.

During charging, unscrew the cell plugs but leavethem in the plug holes. Ventilate well, especially if thebatteries are charged in an enclosed space.

WARNING! Always switch off the charging cur-rent before the charging clips are removed.Never confuse the positive (+) and negative (-)poles on the batteries. This can bring about seri-ous arcing and can cause an explosion.

For so-called quick charging special instructions ap-ply. Quick charging can shorten battery life, andshould therefore be avoided.

44

Shutdown

Preservative measures must be taken to ensure the engine and its associated equipment is not damaged duringshutdowns of two months or more. It is important that this is done in the correct manner, and that nothing is for-gotten. For this reason, we have compiled a check list covering the most important points.

Before shutting down for long periods, an authorized Volvo Penta workshop carry out an inspection.Have any faults and defects remedied, so that the equipment is in working order the next time it is started.

WARNING! Before starting maintenance work, read the “Maintenance” chapter carefully. It contains instruc-tions on how to carry out the work safely and correctly.

WARNING! Some preservative oils are flammable. Some are also dangerous to inhale. Ensure good ventilation. Use a mask when spraying.

IMPORTANT! Pay attention to the following when washing with a power washer: Never aim the water jet atseals, rubber hoses or electrical components.

Preservation

• For shutdowns of up to 8 months:change the oil and engine oil filters and afterwardsrun 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 nextpage.

• Check that the coolant offers sufficient frost pro-tection. Top up as necessary. Alternatively, drainthe coolant (also drain the coolant filter).

• Drain water and contamination from the fuel filtersand fuel tank. Fill the fuel tank completely, toavoid condensation.

• Disconnect the battery cables, clean and chargethe batteries. Trickle charge the batteries duringthe shutdown period. A poorly charged batterycan freeze and burst.

• Clean the outside of the engine. Do not use a highpressure washer for engine cleaning. Touch uppaint damage with Volvo Penta original paint.

• Spray the components of the electrical systemwith water-repellent spray.

• Check and rust-proof any control cables.

• Put a note on the engine with the date, type ofpreservation and the preservative oil used.

• Cover the engine air inlet, exhaust opening andengine if necessary.

45

Shutdown

Preservation of the lubrication and fuel systems for more than 8 months’ shutdown:

• Drain the engine oil and fill with preservativeoil* to just above the MIN-mark on the dipstick.

• Connect the fuel supply and return lines to acanister filled with 1/3 preservative oil* and2/3 dieselfuel.

• Purge the fuel system.

Returning to service

• Remove any covers from the engine, air filter andexhaust pipe.

• Top the engine up with the correct grade of oil, ifnecessary. Install a new oil filter if the filter wasnot changed 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 about2 liters of the fluid in the cannister have beenused. Stop the engine and connect the perma-nent fuel pipes.

• Drain the preservative oil from the engine.

• To continue, follow the instructions on the previ-ous page.

* Preservative oils are sold by oil companies.

• Close drain taps and fit drain plugs if necessary.

• Check coolant level. Top up as necessary.

• Connect the fully charged batteries.

• Start the engine and warm it through at fast idlewith no load.

• Check that no oil, fuel or coolant leaks arepresent.

46

Touble Shooting

A number of symptoms and possible causes of engine malfunctions are described in the table below. Always con-tact your Volvo Penta dealer if any problems occur which you cannot solve by yourself.

WARNING! Read the safety precautions for maintenance and service in the chapter “Safety precautions” be-fore starting work.

The diagnosis button lamp flashes Refer to the “Diagnostic information” chapter

Engine cannot be stopped 2, 4

Starter motor does not rotate 1, 2, 3, 4, 5, 6, 7, 24

Starter motor rotates slowly 1, 2

Starter motor rotates normally but engine does not start 8, 9, 10, 11

Engine starts but stops again 8, 9, 10, 11, 13

Engine does not reach correct operating rpm at full throttle 9, 10, 11, 12, 13, 21, 25, 26

Engine runs roughly 10, 11, 27

High fuel consumption 12, 13, 15, 25

Black exhaust smoke 12, 13

Blue or white exhaust smoke 14, 15, 22

Lubrication oil pressure too low 16

Coolant temperature too high 17, 18, 19, 20

Coolant temperature too low 20

No, or poor charge 2, 23

1. Discharged batteries

2. Poor contact/open circuit inelectrical 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, orparaffin fraction separation infuel at low temperature)

10. Air in the fuel system

11. Water/contamination in fuel

12. Faulty injection pumps

13. Insufficient air supply to theengine:– clogged air filter– air leakage between the turbo

and the engine’s intake pipe– dirty compressor part in the

turbocharger– faulty turbocharger– poor engine room ventilation

14. Coolant temperature too high

15. Coolant temperature too low

16. Oil level too low

17. Coolant level too low

Symptoms and possible causes

18. Air in the coolant system

19. Faulty circulating pump

20. Defective thermostat

21. Blocked charge air cooler

22. Oil level too high

23. Alternator drive belt slips

24. Water entry into engine

25. High back pressure in exhaustsystem

26. Break in “Pot+” cable to pedal

27. Faulty adjustment, enginespeed regulator/actuator

47

• Fault codes can also be deciphered by means ofthe VODIA tool. Refer to the “VODIA User’sGuide” for advice on use.

The fault is simultaneously stored in the control unitmemory. When the fault has been attended to and theignition is switched off and on again, the fault disap-pears as active.

Inactive faults

• DCU – the fault is indicated as passive

• CIU – the diagnostic lamp goes out

• DU – the fault message disappears (inactivefaults cannot be deciphered)

• “Easy Link” – the lamp on the alarm panel goesout

Effect on engineEngines are affected differently, depending on the se-verity of the fault discovered by the diagnostic function.

A fault message in the form of a fault code is alwaysgenerated when a malfunction is discovered by the di-agnostic function.

Engines are affected differently, depending on the se-verity of the fault.

• The engine is not affected

• Engine drops to idle rpm

• Engine torque is restricted to a certain amount

• Engine is stopped

Fault messagesIf the diagnosis function detect a disturbance in thesystem, this is reported using fault codes/fault mes-sages via the instruments.

Both active (unactioned) and passive (actioned) faultsare stored in the control unit.

Refer to the “Operation” heading for deciphering faultcodes/fault messages.

All fault codes and fault messages are found in thefault code list, with information about the reason, reac-tion and measures to be taken; refer to the “Faultcodes” chapter

NOTE! All instruments are accessories

Active faults

DCU (Display Control Unit)

• The text “!! ENGINE WARNING !!” is shown onthe display.

NOTE! You can choose the language that the informa-tion is presented in.

CIU (Control Interface Unit)

• the diagnostic lamp starts to flash.

• “Easy Link” instrument (only with CIU)

- the relevant lamp on the alarm panel lights up

- after the diagnostic button has been pressed, thefault code is shown as text on the tachometerdisplay.

DU (Display Unit)

• Either “WARNING!” or “ALARM STOP” (a buzzersounds) will be shown on the display, dependingon the severity of the fault.


The diagnostic function monitors and checks that the EMS 2 system is functioning normally.

The diagnostic function has the following tasks:

• Detecting and locating malfunctions

• Reporting detection of malfunctions

• Providing guidance when troubleshooting

Diagnostic Function

Diagnostic Function

48

OperationWhen a malfunction has occurred and the diagnosticsystem has generated one or more fault codes, theseare deciphered differently depending on the equipmentused; refer to “Fault code messages”.

If the system indicates that a fault code has beenset:

1. Reduce engine speed to idling. Do not switch ofthe engine. (If the engine is switched of faultcodes may disappear.)

2. For DCU/DURead the fault code from the display; refer to“Reading fault codes via the DCU” or “Decipheringfault codes via the DU”.

For CIUpress the diagnostic button and read the faultcode, by observing the flashing of the diagnosticlamp; refer to “Deciphering fault codes via the di-agnostic lamp, CIU”

3. Look up the fault code in the list in the “FaultCode” chapter and take the recommended mea-sures.

Reading fault causes via the DCU(Display Control Unit)When a fault code is set, the following text is shownon the display:

“!! ENGINE WARNING !!”

alternated with

“Press SEL for information”.


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


3. Press the ESC button to leave the fault list.

NOTE! To access the fault list when no fault code hasbeen set, press the SEL button and select “Diagnos-tics” from the menu.

Reading fault codes via the DU(Display Unit)Depending on the severity of the fault the text, either“WARNING!” or “ALARM STOP” (a buzzer sounds).

1. Press any button to get to the fault list.

The fault list shows:- Running hours

- Fault message


3. Press ACK to acknowledge the fault code. Thedisplay background will change color (the buzzerstops sounding).

4. Press EXIT to leave the fault list.

49

Erasing fault codesFault codes must be erased by means of the VODIAtool.

Reading fault codes via the diagnosticlamp on the instrument panel, CIUWhen the system has discovered a malfunction, thediagnostic lamp starts to flash. If the diagnostic but-ton is depressed and then released, a fault code isflashed.The fault code consists of two groups of flashes, sep-arated by a pause of two seconds. A fault code is ob-tained by counting the number of flashes in eachgroup.

Example: pause = Fault code 2.4

The fault code is stored and can be deciphered aslong as the malfunction remains. You can find infor-mation about cause, action and measures in the faultcode list in the “Fault Code” chapter.

Read the fault code as follows:

1. Press the diagnostic button.

2. Release the diagnostic button and make a note ofthe fault that is flashed out.

3. Repeat items 1-2. A new fault code is flashed outif more are stored. Repeat until the first fault codeis repeated.

NOTE! When the first fault code recurrs all the faultcodes have been read.If the diagnostics button is depressed after the faulthas been corrected and the fault code deleted, thecode 1.1, “No fault” will be shown.

Reading the fault codes via an “Easylink” instrument (only with a CIU)When the system has discovered a malfunction, it isreported by the diagnostic lamp which starts to flash.

1. Press the diagnostic button: the fault code isshown as text on the tachometer display.


3. When the fault has been rectified, the fault codedisappears from the display and the diagnosticlamp goes out.

50

Fault codes

WARNING! Read the safety precautions for maintenance and service in the chapter “Safety information”before starting work.

NOTE! Reading the fault codes below, such as Code 2.1, PID/SPN 97, where 2.1 is a flash code indicated by aflashing diagnostic lamp. PID/SPN 97 is deciphered with the VODIA diagnostic tool. When using DCU or DU, thefault code is displayed as plain text.For a further explanation, see “Reading fault codes”.

NOTE! Refer to “Wiring schedule CIU and DCU” for references to the sockets in the electrical connectors on theengine control unit.

Code 1.1 No faults

There are no active faults.

Code 2.1, PID/SPN 97. Water in fuel

Reason:

• Water in fuel.

Reaction:

• None.

Action:

• Drain the fuel pre-filter.

Code 2.2, PID/SPN 111. Coolant level

Reason:

• Low coolant level.

Reaction:

• Engine control unit reduces engine power (unlessthe protection has been shut off with the VODIAdiagnostic 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 level sensor cable is notdamaged.

• Check coolant level sensor function.

Code 2.4, SID 22/SPN 637Engine rpm sensor, flywheel

Reason:

• No signal.

• Abnormal frequency.

• Intermittent signal from the sensor.


Reaction:

• Engine is very difficult to start and runs roughlywhen it starts.

Action:

• Check that the sensor connector is correctly in-stalled.

• Check that the engine rpm sensor cable is notdamaged.

• Check that the engine rpm sensor is correctly in-stalled in the flywheel casing.

• Check engine rpm sensor function.

51

Fault codes

Code 2.5, SID 21/SPN 636Engine rpm sensor, cam disc

Reason:

• No signal.

• Abnormal frequency.


Reaction:

• Engine takes longer to start than normal. Engineruns normally when running.

Action:

• Check that the engine speed sensor connector iscorrectly installed.

• Check that the engine rpm sensor cable is notdamaged.

• Check that the engine rpm sensor is correctly in-stalled in the upper timing gear cover.

• Check engine rpm sensor function.

Code 2.6, PID/SPN 190. Engine speed

Reason:

• Engine rpm too high.

Reaction:

• None.

Action:

• After the engine has stopped, trace the reason forthe high rpm.

Code 2.8, PPID 132/SPN 608Engine rpm potentiometer connected to CIU

Reason:

• Short circuit to positive (+) or negative (-).


Reaction:

• Engine drops to idle rpm.

• Rpm is “frozen”.

Action:

• Check that the potentiometer is correctly con-nected.

• Check that the potentiometer cable is not dam-aged.

• Check potentiometer function.

Code 2.9, PID/SPN 97Indicator for water in fuel

Reason:

• Short circuit.

• Open circuit.

• Fault in indicator.

Reaction:

• None.

Action:

• Check the indicator cables for breaks and shortcircuits.

• Check indicator function. Change indicator as nec-essary.

Code 3.1, PID/SPN 100. Oil pressure sensor

Reason:


• Open circuit.

Reaction:

• None.

Action:

• Check that the oil pressure sensor cable is notdamaged.

• Check that the oil pressure sensor is correctlyconnected.

Code 3.2, PID/SPN 105Charge air temperature sensor

Reason:


• Open circuit.

Reaction:

• None.

Action:

• Check that the charge air temperature sensor con-nector is correctly installed.

• Check that the charge air temperature sensorcable is not damaged.

• Check that the charge air temperature sensor iscorrectly installed.

• Check charge air temperature sensor function.

Fault codes

52

Code 3.3, PID/SPN 110Coolant temperature sensor

Reason:


• Open circuit.

Reaction:

• Preheating is also activated when the engine is hot.

Action:

• Check that the coolant temperature sensor con-nector is correctly installed.

• Check that the coolant temperature sensor cableis not damaged.

• Check that the coolant temperature sensor is cor-rectly installed.

• Check coolant temperature sensor function.

Code 3.4, PID/SPN 106/102Charge pressure sensor

Reason:


• Open circuit.

Reaction:

• Engine smokes more than normally during accel-eration/load increase.

Action:

• Check that the charge air pressure sensor con-nector is correctly installed.

• Check that the charge air pressure sensor cable isnot damaged.

• Check that the charge air pressure sensor is cor-rectly installed.


Code 3.5, PID/SPN 106/102. Charge pressure

Reason:

• Charge pressure too high.

Reaction:


Action:

• Check turbocharger compressor function.


• Check fuel volume/injector.

Code 3.6, PID/SPN 94. Fuel pressure sensor

Reason:


• Open circuit.

Reaction:

• None.

Action:

• Check that the fuel pressure sensor connector iscorrectly installed.

• Check that the fuel pressure sensor cable is notdamaged.

• Check that the fuel pressure sensor cable is cor-rectly installed.

• Check fuel pressure sensor function.

Code 3.8, PID/SPN 94. Fuel pressure

Reason:

• Low supply pressure.

Reaction:

• None.

Action:

• Check if it is possible to build up pressure with thehand pump.

• Check the fuel filter.

• Check the fuel pre-filter.

Code 3.9, PID/SPN 158. Battery voltage, EMS

Reason:

• Faulty battery cables, battery.

• Faulty alternator.

Reaction:

• None.

Action:

• Check the supply voltage to the control unit.

53

Fault codes

Code 4.6, PPID 3/SID 39/SPN 677Start output/Starter motor relay

Reason:


• Activated for too long.

Reaction:

• Engine cannot be started.

• The engine starts as soon as the ignition isswitched on.

Action:

• Check that the starter switch connections are notdamaged.

• Check that the wiring to the starter key is notdamaged.

Code 4.8, PPID 6/SPN 970Stop input EMS

Reason:

• Short circuit to negative (-).

• Open circuit.

Reaction:

• Engine can only be stopped by the auxullary stop.(Or via the CAN-link.)

Action:

• Check that the connections and harness are notdamaged.

Code 5.2, PPID 4/SPN 520194Start input CIU

Reason:



Reaction:


• The engine starts as soon as the ignition isswitched on.

Action:



Code 5.3, PPID 6/SPN 520195. Stopp input, CIU

Reason:


• Open circuit.


Reaction:

• Engine can only be stopped with the auxiliary stop(AUX STOP) on engine.

• Engine stops. A fault code is displayed for 40seconds and the engine cannot be started duringthis time. When a fault code is active, the enginecan be started but not stopped.

Action:



Code 5.4, PID 45/SPN 626. Preheater relay

Reason:


• Open circuit.

Reaction:

• Preheating can not be activated.

• Preheating is constantly connected.

Action:

• Check that the relay input cable is not damaged.

• Check relay function.

Fault codes

54

Code 6.1, PID/SPN 110. Coolant temperature

Reason:

• Coolant temperature is too high.

Reaction:


Action:

• Check the coolant level.

• Check the charge air cooler (cleanliness).

• Check if there is air in the cooling system.

• Check the pressure cap on the expansion tank.

• Check coolant temperature sensor function.

• Check thermostat function.

Code 6.2, PID/SPN 105. Charge air temperature

Cause:

• The charge air temperature is too high.

Reaction:

• Engine control module reduces engine power (un-less the protection has been shut off with theVODIA diagnostic tool).

Remedy:

• Check coolant level.

• Check the charge air cooler (cleanliness).


• Check thermostat function.

Code 6.4, SID 231/SPN 639. Data link (CAN), CIU

Reason:

• Faulty data link (CAN), CIU.

Reaction:

• Instruments and warning lamps stop working.

Action:

• Check that the 8-pin connector is not damaged.

• Check that the cables between the CIU and theengine control unit are not damaged.

Code 6.5, SID 231/SPN 639/2017/PSID 201Data 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 bestopped with the auxiliary stop (AUX-stop).

Action:

• Check that the 8-pin connector is not damaged.

• Check that the cables between the CIU and theengine control unit are not damaged.

• Check that sockets 11 and 12 in the connector onthe CIU are not damaged.

Code 6.6, PID/SPN 100. Oil pressure

Reason:

• Oil pressure is too low.

Reaction:


Action:

• Check oil level.

• Check that the oil filters are not blocked.

• Check system pressure valves and safety valvesin the oil system.

• Check oil pressure sensor function.

Code 6.9, PID/SPN 158Battery voltage, CIU

Reason:


• Faulty alternator.

• Faulty battery, battery cables.

Reaction:

• Engine start problems.

Action:

• Check the supply voltage from the control unit.

• Check the battery.

• Check the alternator.

• Check the 8-pin connector.

55

Fault codes

Code 7.1, SID 1/SPN 651Injector, cylinder #1

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 fuel supply pressure.

• Check the valve clearance.

• Perform a compression test and checkcylinder #1.


Reason:



Reaction:


• Abnormal sound.


Action:







Reason:



Reaction:


• Abnormal sound.


Action:







Reason:



Reaction:


• Abnormal sound.


Action:






Fault codes

56


Reason:



Reaction:


• Abnormal sound.


Action:







Reason:



Reaction:


• Abnormal sound.


Action:






Code 8.3, SID 42/SPN 679.Injection pressure, 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 1239Pressure in distribution manifold

Reason:

• Leakage in the high pressure fuel system.

• Leakage in the high pressure supply pipe to the in-jector.

Reaction:


Action:


Code 8.3, PSID 97/SPN 679. Pressure valve

Reason:

• Leakage in the PRV (Pressure Release Valve).

• The PRV stuck closed.

• The PRV stuck open.

Reaction:


Action:


57

Fault codes

Code 8.3, PID/SPN 164. Injection pressure

Reason:

• Faulty fuel supply.

• Faulty fuel pump.

• Faulty cables.

• Faulty sensor.

Reaction:

• Warning lamp lights up.

• Engine control unit limits engine power.

Action:

• Check the cables.

• Check sensor.

• Check the filter.

• Check the fuel pumps.

Code 8.4 PPID 55/SPN 1136 EMS temperature

Reason:

• Electrical fault, damaged sensor.

• Control unit incorrect assembly, too hot.

Reaction:

• None

Action:

• Check the control unit installation. Recommendedambient temperature is 50 °C.

Code 8.6, SID 70/SPN 729. Preheating sensor

Reason:

• Faulty cables.

• Faulty preheating relay.

Reaction:

• Not possible to activate preheating.

Action:

• Check cables.

• Check the preheating relay.

Code 9.3, SID 232/221/SPN 620/1079/1080Voltage 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 pressuresensors.

• Low power.

• Oil pressure and oil temperature instruments show0.

Action:

• Check that the oil pressure and charge air pres-sure sensors are not damaged.

• Check the oil pressure sensor and charge air pres-sure sensor.

Code 9.8, SID 254/SPN 629.Fault in control unit, CIU

Reason:

• Faulty EEPROM, CIU.

• Faulty flash memory, CIU.

• Fault in control module, CIU.

Reaction:

• CIU returns to factory setting.

• Engine drops to idle rpm.


Action:

• Re-program the unit.

Fault codes

58

Code 9.9, SID 240/SPN 639, Memory fault in EMS

Reason:

• 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.

59

Technical data

General

Type designation TAD734GE

Power Refer to the sales literature

Torque Refer 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

60

Technical data

Fuel System

Feed pumpSupply pressure, at 1200 rpm: ................................... 0.2 MPa (29 psi)

Fuel specification ....................................................... Refer to the “Maintenance; fuel system” chapter

Lubrication SystemOil grade ................................................................... Refer to the “Maintenance, lubrication system” chapter

Oil change volume, including 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 just touches)

Lubrication oil pumpType .......................................................................... Gearwheel oil pump

Technical data

61

Electrical systemSystem voltage .......................................................... 24V

Alternator:voltage/max. current density ................................... 28V/80A

Cooling SystemType .......................................................................... Pressurized, sealed

Pressure valve, max. opening pressure: .................... 120 kPa (17.4 psi)

Volume (engine)TAD734GE: ............................................................ 8 liter (2.11 US gal)

ThermostatQuantity and type ....................................................... 1 pc piston thermostatOpening temperature .................................................. 83 °C (181 °F)Fully open at .............................................................. 103 °C (217 °F)

Notes...........................................................................................................................................................................................

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Please note that this offer is valid for 12 months from the date of deliveryof the engine, after this it is subject to availability.

Post or fax this coupon to:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSwedenFax: +46 31 545 772

Orders can also be placed viathe Internet:http://www.volvopenta.com/manual/coupon

Yes please,I would like an operator’s manual in English at no charge.

Publication number: 7747302

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Bitte beachten Sie, dass das Angebot für die Dauer von 12 Monaten ab demLieferdatum des Motors gilt, danach nur noch bis zum Aufbrauchen des Lager-bestandes.

Schicken Sie den Couponper Post oder als Fax an:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSchwedenFax: +46 31 545 772

Die Bestellung kann auch überdas Internet erfolgen:http://www.volvopenta.com/manual/coupon

Ja,ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.

Publikationsnummer: 7747303

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Noter que l’offre est valable 12 mois à partir de la date de livraison dumoteur, puis seulement dans la mesure des stocks disponibles.

Envoyez ou faxez le bon decommande à:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSuèdeFax: +46 31 545 772

Vous pouvez également passerla commande par Internet:http://www.volvopenta.com/manual/coupon

Oui merci,Je souhaite recevoir un manuel d’instructions gratuit en français.Numéro de publication: 7747304

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Notare che la validità dell’offerta è garantita solo per 12 mesi dalla consegna delmotore, dopodiché si procederà fino ad esaurimento scorte.

Spedire il tagliando per posta oper fax a:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSveziaFax: +46 31 545 772

L’ordinazione può essere fattaanche su Internet:http://www.volvopenta.com/manual/coupon

Sì, grazie,desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana.

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2

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Observe que la oferta es válida durante 12 meses a partir de la fecha de entregadel motor. A partir de la fecha de finalización de la oferta, la misma es válida siem-pre que haya existencias.

Franquear o enviar fax a:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSueciaFax: +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

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Observera att erbjudandet gäller i 12 månader från motornsleveransdatum, därefter endast i mån av tillgång.

Posta eller faxa kupongen till:Dokument & Distribution centerOrdermottagningenARU2, Avd. 64620SE-405 08 GöteborgSverigeFax: +46 31 545 772

Beställningen kan även görasvia internet:http://www.volvopenta.com/manual/coupon

Ja tack,jag vill kostnadsfritt ha en instruktionsbok på svenska.

Publikationsnummer: 7747301

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Denk eraan dat de aanbieding geldt tot 12 maanden na levering van demotor, daarna nog slechts indien beschikbaar.

Stuur of fax de coupon naar:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgZwedenFax: +46 31 545 772

U kunt ook bestellen viainternet:http://www.volvopenta.com/manual/coupon

Ja graag,Ik wil kosteloos een instructieboek in het Nederlands ontvangen.

Publicatienummer: 7747308

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Ota huomioon, että tarjous on voimassa 1 vuoden ajanmoottorin luovutuspäivämäärästä, sen jälkeen vaintuotteen saatavuuden perusteella.

Postita tai faksaa kuponkiosoitteella:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgRuotsiFax: +46 31 545 772

Tilauksen voi tehdä myösInternetissä:http://www.volvopenta.com/manual/coupon

Kyllä kiitos,haluan suomenkielisen ohjekirjan veloituksetta.

Julkaisunumero: 7747307

Nimi

Osoite

Maa 4220

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Notar que a oferta é válida por um período de 12 meses a partir da data de entre-ga do motor. Depois desse período, a oferta é válida consoante a disponibilidade.

Envie o talão pelo correio ouum fax para:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSuéciaFax: +46 31 545 772

A encomenda também podeser feita através da Internet:http://www.volvopenta.com/manual/coupon

Sim, obrigado(a)!Gostaria de receber gratuitamente um manual de instruções em português.

Número de publicação: 7747309

Nome

Endereço

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