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Fuel System

WARNING!

Fire hazard. When carrying out work on the fuel system
make sure the engine is cold. A fuel spill onto a hot
surface or an electrical component can cause a fire.
Store fuel soaked rags so that they cannot cause fire.

Store fuel-soaked rags so that they cannot cause fire.

IMPORTANT:

Always observe the greatest cleanliness during
refueling and work on the fuel system.
Only use the grades of fuel recommended in the fuel
specification.

Draining condensate, fuel system

1 Put a collection vessel under the fuel filter to collect

the condensate and fuel.

2 Open the drain nipple (1) in the base of the fuel pre-

filter.

3 Tighten the drain tap (1) when fuel without water

starts to run out.

P0002101

Maintenance

85

47711089 09-2018 © AB VOLVO PENTA

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Summary of Contents for 13L

Page 1: ...Operator s manual 13L EATS Exhaust Aftertreatment System EPA CARB ...

Page 2: ...fornia to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust when operating servicing and maintaining the engine Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the outside Wear gloves or wash your hands frequently when servicing the vessel Do not modify or tamper with the exhaust system Do...

Page 3: ...l Interface Unit 44 Easy Link Instruments 44 Starting 45 Before Starting 45 Starting the Engine 46 DCU Display Control Unit 46 DCU II Display Control Unit 47 Starting in Extreme Cold 47 Never Use Start Spray 48 Starting Using Auxiliary Batteries 48 Operation 49 Reading the Instruments 49 Alarms 49 Maneuvering 50 Operation at low load 50 Engine Shutdown 52 Before Engine Shutdown 52 Stop the Engine ...

Page 4: ...fuel system 85 Engine Fuel Filter Replacement 86 Fuel Pre filter Change 87 Fuel system bleeding 88 Cooling System 89 Coolant Level Checking and Topping Up 90 Coolant Draining 91 Charge Air Cooler External Cleaning 91 Cooling System Cleaning 92 Inlet and Exhaust System 94 Filling AdBlue DEF 94 AdBlue DEF Pump Filter Change 97 AdBlue DEF Pump Filter Change 100 Electrical System 103 Main switch 103 E...

Page 5: ...afely and correctly Pay careful attention to the safety instructions included in the manual As the owner of a Volvo Penta engine you become part of a worldwide network of dealers and service workshop that assist you with technical advice service requirements and replacement parts Contact you nearest authorized Volvo Penta dealer for assistance It is possible to buy additional literature about your...

Page 6: ...f not avoided result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate personal injury IMPORTANT Indicates a situation which if not avoided could result in property damage NOTICE Used to draw attention to important inf...

Page 7: ... give the engine and engine compartment a visual check before the engine is started and after operations once the engine has stopped This helps you to quickly discover fuel coolant or oil leakages or any other abnormality that has occurred or is about to occur Personal safety equipment CAUTION Always use appropriate safety equipment Personal protective equipment does not eliminate the risk of inju...

Page 8: ...clothes and rags Wash regularly especially before eating Wear suitable protective creams to prevent skin from drying out and to facilitate cleaning Fire safety WARNING Fire and Explosion Risk Accidental spark could ignite fuel vapors All fuels as well as many lubricants and chemicals are flammable Do not allow open flames or sparks near them Smoking forbidden Hydrogen from the batteries is also ve...

Page 9: ...nt facility for correct handling as must any used lubricating oil contaminated fuel paint residue solvents degreasers and wash residue Prevent start of the engine WARNING Immobilize the engine by turning off the power supply with the main switch es and lock it them in the off position before starting work Place a warning notice at the main switch If the engine is equipped with BMS Battery Manageme...

Page 10: ... lead to serious personal injury Be careful to avoid hot surfaces exhaust pipes turbochargers charge air manifolds start elements etc and hot fluids in pipes and hoses on engines that are running or have just stopped Re install all protective covers that were removed during maintenance work before starting the engine Information on the engine IMPORTANT Make sure that all warning and information de...

Page 11: ...ating compressor turbine can in addition cause serious personal injuries Before any work on the electrical system WARNING Always stop the engine first Then disconnect the current at the main switches and any external power supply before working on the electrical system to minimize the risk of electrical hazards IMPORTANT Never disconnect the current using the main switches when the engine is runni...

Page 12: ...ine is still hot Steam or hot coolant can spray out and system pressure is lost Open the filler cap slowly and release the pressure in the cooling system if the filler cap or valve must be opened or if a plug or a coolant hose must be removed from a hot engine Hot oil under pressure CAUTION Hot oil can cause burns Avoid getting hot oil on the skin Ensure that the lubrication system is not pressuri...

Page 13: ...ty goggles Be extremely careful when searching for leaks in the fuel system high pressure circuits There is very high pressure in the jet from pipes and injectors The fuel may penetrate the tissue and cause serious risk of blood infection septicemia Handling of fuel pipes IMPORTANT High pressure pipes for fuel must not be bent or straightened under any circumstances Cracks may occur Damaged pipes ...

Page 14: ... highly corrosive Rinse immediately with copious amounts of water if the electrolyte gets in your eyes Search directly after the rinsing help by medical staff If it comes electrolyte to unprotected skin wash immediately with soap and water Layout of the battery compartment IMPORTANT Make sure the battery compartment is designed according to current safety standards Cleaning the engine and componen...

Page 15: ...meticulous cleanliness when handling system components Even minimal amounts of dirt could cause a breakdown Adjustment of the clutch CAUTION Clutch adjustments must be carried out with the engine stopped Safety Information 13 47711089 09 2018 AB VOLVO PENTA ...

Page 16: ... the functionality described in this manual About this manual This Operator s Manual contains the information required for the correct safe operation and maintenance of your Volvo Penta engine Read the Operator s manual carefully and learn to handle the engine and other equipment in a safe manner before you start the engine Warranty Your new Volvo Penta engine is covered by a limited warranty subj...

Page 17: ...ecked more carefully during the first days Adjustments may be necessary to compensate bedding in of the friction plates Fuel oils and coolant Only use the fuels and oils recommended in the Operator s Manual since other grades may cause malfunctions increased fuel consumption and possibly shorten the life of the engine Always change the oil oil filters and fuel filter at the specified maintenance i...

Page 18: ...orized dealers The authorized dealers are Volvo Penta product specialists and have the accessories genuine parts test equipment and special tools needed for high quality service and repair work Always observe the maintenance intervals in the manual the complete Service Protocol can be found at volvopenta com Remember to note the engine transmission identification number when you order service and ...

Page 19: ...ing exhaust emissions in the same time as the fuel consumption has been improved Through regular maintenance the Volvo Penta engines retain its low fuel consumption and low emissions We hope that you will be keen to preserve these qualities Always follow the directions in the Operator s Manual regarding fuel grades operation and maintenance to avoid unnecessary environmental impact Contact your Vo...

Page 20: ...ility of the operator user to ensure that no intentional misuse of the engine takes place Volvo Penta maintenance and service intervals must be complied with Any case of malfunction must be rectified without delay Only use genuine Volvo Penta parts or spare parts with the same quality as genuine Volvo Penta parts Volvo Penta recommends that service to injection pumps pump settings and injectors al...

Page 21: ...arying depending on the operating conditions For filling instructions refer to Filling AdBlue DEF page 94 If the exhaust gas control system does not work correctly the operator will be informed by a fault indication Volvo Penta Dealer Network The Volvo Penta global network of authorized dealers is at your service We strongly recommend that you take your product to an authorized Volvo Penta dealer ...

Page 22: ...works A dedicated operator will support you all the way through your case and keep you updated on status and progress Whenever on site assistance or technical support is needed the operator will put you in contact with the closest Volvo Penta dealer that can support your product Phone numbers Find your Volvo Penta Action Service phone number and more information on www volvopenta com Introduction ...

Page 23: ...n industrial diesel engines All of the engines are equipped with electronically controlled fuel management EMS turbocharger charge air cooler thermostatically controlled cooling systems and electronic speed control The engines are fitted with SCR systems Selective Catalytic Reduction in order to reduce emissions TAD1371VE TAD1375VE are also fitted with EGR Exhaust Gas Recirculation 21 47711089 09 ...

Page 24: ...re controlled electronically via the fuel valves in the injectors The control unit receives signals from sensors and monitors in order to determine when the fuel valve must open and close This means the engine always receives the correct fuel volume under all operating conditions which means lower fuel consumption and the lowest possible exhaust emission Diagnostic function The purpose of the diag...

Page 25: ...orm harmless nitrogen and water vapor which occur naturally in our surroundings The solution is not flammable or harmful to health with normal use it is however very corrosive to metals especially copper and aluminum IMPORTANT The use of solution that do not fulfill the ISO 22241 standard will compromise the aftertreatment system performance increase emissions Any warranty claims will be rejected ...

Page 26: ...n on the instrument panel depending on application not if only the engine power supply is disconnected If the system is not drained properly solution may squirt out if the hoses are disconnected CAUTION The EATS system needs time to for automatically drainage and depressurizing Wait at least two minutes after the engine been turned off before removing the AdBlue DEF hoses Overview The system compr...

Page 27: ... level in the tank falls below the set limit the level sensor in the tank transmits a signal that stops AdBlue DEF dosing A fault code is set in the engine control unit a warning lamp lights up and a fault message is shown on the control panel If solution is not added injection into the exhaust pipe will cease and engine torque and engine speed will be limited When solution is added the fault mess...

Page 28: ...d The standard system can handle thawing from 40 C 40 F The system is emptied at shut down in order to prevent expansion damage due to freezing IMPORTANT Hoses must be handled carefully and not twisted or bent excessively in order to avoid damaging the heating system Storage IMPORTANT To prevent breakdown and evaporation during longterm storage AdBlue DEF may not be stored at temperatures higher t...

Page 29: ...ioxide However do not allow the solution to come into contact with other chemicals or be mixed with other chemicals When handling AdBlue DEF it is important that electrical connectors are connected or well encapsulated The solution is corrosive toward certain metals such as copper and aluminum Should oxidation occur it cannot be removed If connectors come into contact with the solution they must b...

Page 30: ...ned from AdBlue DEF so that the liquid or crystals are not transferred to other parts and cause them damaged Contact with AdBlue DEF skin contact flush with copious amounts of water and remove contaminated clothing eye contact flush thoroughly for several minutes contact physician as necessary inhalation breathe fresh air and contact physician as necessary p0013225 Presentation 28 47711089 09 2018...

Page 31: ...al functions such as engine control monitoring diagnostics and parameter setting The menus in the DCU system can be used to check and in some cases to set a number of different functions in the EMS system NOTICE Settings and what engine data that appears in the display may vary depending on installation and engine model NOTICE The menus and illustrations shown here are the English version The lang...

Page 32: ... 1 LED display 6 ON OFF Starts and stops the system 2 START Starts the engine 7 Scroll downwards in menus 3 SPEED Reduces engine rpm 8 SEL Selects in menus 4 SPEED Increases engine rpm 9 Scroll upwards in menus 5 STOP Stops the engine 10 ESC Return to previous menu selection Instruments and Controls 30 47711089 09 2018 AB VOLVO PENTA ...

Page 33: ...e activated with temperatures below 0 C 32 F Governor mode activation of droop Diagnostics shows fault codes as text Trip reset resets trip data Setup parameter setting Information shows the currently applicable hard software data sets and engine identification for the engine and DCU data Engine data shows relevant engine data Engine speed can be controlled with the SPEED and SPEED buttons rpm Cha...

Page 34: ...SEL the text Preheat requested will be shown The display automatically returns to the Engine Data menu Governor mode activates shuts off droop To set the droop level refer to the Setup Governor gradient or Governor droop menu Select Isochronous mode or Droop mode with the SEL button Diagnostics shows the error list containing the 10 latest active and inactive faults The fault codes are shown as te...

Page 35: ...e engine Run The stop input must be connected to voltage to run the engine Customer parameter setting alarm limits Refer to Customer parameter Versatile and Customer parameter Gen set Throttle input setting setting of engine speed control and voltage limits Refer to Throttle input setting Display setting setting the display refer to Display setting Customer parameter Versatile Idle engine speed se...

Page 36: ...ut down with overspeed alarm Refer to Overspeed limit to activate the alarm limit for the excess rpm alarm Oil temp warning limit C setting alarm limit for oil temperature Coolant temp limit C setting alarm limit for coolant temperature Throttle input setting rpm control setting throttle operation Set throttle mode OFF engine rpm is controlled via the DCU panel ext throttle input engine speed is c...

Page 37: ...ghtness setting Information shows the data for the engine and DCU Engine hardware Id engine control unit part number Engine software Id engine control unit software part number Engine dataset1 Id engine data set 1 part number Engine dataset2 Id engine data set 2 part number Vehicle Id chassis number DCU hardware Id DCU part number DCU software Id DCU software part number DCU dataset1 Id DCU data s...

Page 38: ...odel Depending on the installation the DCU II can also be used as presentation display only NOTICE The menus and illustrations shown here are the English version Refer to the section Settings to change the display language Turn On Off the ignition Start the engine Reduce engine rpm Increase engine rpm Stop the engine Scroll upwards in menus Select and confirm in menus Scroll downwards in menus Ret...

Page 39: ...n Alarms and messages Messages to the operator are of three types color coded according to degree of severity When a message is shown on the display press to reach the diagnostic menu to get more information regarding registered faults and instructions for remedial actions ALARM ALARM red text the system has detected a serious fault Volvo Penta recommends to immediately contact a qualified worksho...

Page 40: ...utton to scroll to the fault concerned and press OK This will also provied information about number of engine hours when the fault became active and the SPN and FMI codes SETTINGS SETTINGS Display Display Set backlight time Set backlight time On OFF sets backlight to run in standby mode On is the default setting Set backlight brightness Set backlight brightness Adjust display backlight brightness ...

Page 41: ...owing menus do not normally need to be changed should a change be necessary it must be carried out by an authorized Volvo Penta technician Refer to the installation manual for further engine information Authorized Volvo Penta dealer or OEM only I O Status I O Status CAN Termination CAN Termination Stop Logic DCU Stop Logic DCU Potentiometer supply Potentiometer supply Speed Control Speed Control C...

Page 42: ... The display will work but may act in an unexpected way The DU is connected between the engine control unit and the CIU or DCU Display modes Press any of button 1 4 to view the function menu for the buttons apperaring in the lower part of the display To leave the menu wait a few seconds or press button 5 EXIT 1 Engine 2 Multi 3 Trip 4 Graph 5 Exit Contrast In the display modes Engine Trip and Grap...

Page 43: ...t windows Press repeatedly on the button that correspond to the window until desired information is shown Trip To display the trip computer press button 3 Trip Trip Fuel since last reset Fuel Rate fuel consumption Trip hours since last reset Engine hours total amount of operating hours Reset by pressing button 3 for three seconds until a beep is heard Graph The information is shown as graphs Press...

Page 44: ...arrows select with the right arrow Units PRESSURE kPa PSI VOLUME LITRE GAL Imperial GAL Fuel rate is adjusted according to volume unit L H GAL H IGAL H TEMPERATURE C F Alarm Status List of active alarms refer to Reading fault codes via the DU Display Unit Instruments and Controls 42 47711089 09 2018 AB VOLVO PENTA ...

Page 45: ...DEMO switches the DEMO mode ON OFF RESTORE DEAFAULTS reset all configuration to default values COM VIEWER displays latest message on communication ports PROG TX transfers content of the application on Flash memory to other CAN units on the same CAN bus ABOUT displays ID NO display serial number EEPROM number of write on EEPROM VERS software version number CHK Flash memory checksum PART No Volvo so...

Page 46: ...ectors and potentiometers is controlled by this link The slow link manages diagnostic information for flashing codes etc Easy Link Instruments TAD1360 65VE The following Easy Link instruments are available Tachometer hours counter fault codes are also displayed on the tachometer display when the diagnostic button is pressed Coolant temperature Oil pressure Oil temperature Battery voltage Alarm pan...

Page 47: ... the STOP side of the dipstick when engine is stopped and the OPERATING side when in operation Open the fuel valves Check the fuel pre filter refer to Draining condensate fuel system page 85 Check the coolant level and that the radiator is not blocked externally Refer to Coolant Level Checking and Topping Up page 90 and Charge Air Cooler External Cleaning page 91 WARNING Do not open the coolant fi...

Page 48: ...t TAD1360 65VE With pre heating 1 Depress the ON OFF button 6 2 Press the SEL button 8 to come to the mainmenu 3 Scroll down to Pre heater with scroll button 7 press SEL button 8 4 In the pre heater menu press the SEL button 8 to select pre heating 5 Press the START button 2 Without pre heating 1 Depress the ON OFF button 6 2 Press the START button 2 Leave the engine to idle for the first 10 secon...

Page 49: ...mend the use of a fuel heater Use a synthetic engine oil of a viscosity recommended for the prevailing temperature to achieve satisfactory lubrication Refer to Viscosity page 109 Synthetic lubricants are able to handle a wider temperature range than mineral based lubricants Pre heat the coolant with a separately installed electric engine heater In extreme cases a diesel fired engine heater may be ...

Page 50: ...ted voltage corresponds to the engine system voltage 2 First connect the red jumper cable to the auxiliary battery then to the flat battery Then connect the black jumper cable to the auxiliary battery and to a location that is somewhere away from the discharged battery e g the main switch negative terminal or the negative terminal on the starter motor 3 Start the engine WARNING Do not touch the co...

Page 51: ...and then regularly during operation NOTICE On engines in continuous operation it is recommended that the lubrication oil level is checked at least every 24 hours Refer to Oil level checking and topping up Alarms If the EMS receives abnormal signals from the engine the control unit generates fault codes and alarms in the form of lamps and audible warnings This is done by means of CAN signals to the...

Page 52: ...nces can be carbon build up on valves piston crowns and the exhaust turbine which could affect engine performance Both conditions can lead to increased oil consumption and eventually external oil leakage from joints in the exhaust system For example leakage could be seen at the exhaust manifold before and after the turbo around the muffler and in worse case even in the exhaust end pipe Consequence...

Page 53: ...posits in the engine and exhaust system to burn off If visible slobber has occurred it can be burned off by running the engine on at least 30 load for about 40 60 minutes Operation 51 47711089 09 2018 AB VOLVO PENTA ...

Page 54: ...n 50 load high idle for approximately 3 minutes is sufficient This allows engine temperature equalization and prevents boiling once stopped and also allows the turbochargers to cool down This contributes to long fault free service life NOTICE Do not turn off the main switch within 30 seconds after turning off the ignition This is in order to save engine data to the engine control unit Stop the Eng...

Page 55: ...hedule For longer breaks in operation During longer breaks in operation it is recommended that the engine is warmed up at least once every two weeks This prevents corrosion in the engine If you expect the engine to be unused for two months or more it should be conserved Refer to Storage page 106 IMPORTANT If there is a risk of freezing the coolant in the cooling system must have adequate antifreez...

Page 56: ...l impact If a malfunction is detected the diagnostic function informs of the occurred fault in the form of a fault code The fault code provides guidance when fault tracing All fault codes and fault messages can be found in the Fault Code Register The operator is warned that there is a malfunction via the instruments Depending on the instrumentation in use the fault message is shown in various ways...

Page 57: ... TAD1371 75VE DIAGNOSTICS If the system detects a malfunction the driver operator is informed via a pop up message on the display The fault codes are listed in the diagnostics menu active fault codes are at the top of the list and are denoted by a green dot For more detailed information regarding the cause and remedies use the arrow buttons to scroll to the fault concerned and press This will also...

Page 58: ...e fault list The fault list shows fault messages and the number of hours of operation when the fault occurred 4 Press ACK to acknowledge the fault code The display background changes color and the buzzer stops The fault must be acknowledged before it can disappear from the fault list 5 Look up the fault code in the Fault Code Register and take the necessary actions 6 Press button 4 for at least th...

Page 59: ... remains Information about causes effects and actions required is available in the Fault Code chapter Do as follows to read off the fault code 1 Press the diagnostics button 2 Release the diagnostics button and note down the fault that is flashed out 3 Repeat items 1 2 A new fault code will be flashed out if more faults are stored Repeat until the first fault code reappears NOTICE When the first f...

Page 60: ...ars from the display and the diagnostics lamp goes out Erasing fault codes The memory of the diagnostic function is reset when the power to the engine is disconnected When the power is switched on again the diagnostic function will check if there are any malfunctions in the system If so a new fault codes is registered If a malfunction has not been corrected it will be registered once again and has...

Page 61: ......

Page 62: ... Please refer to Alarm handling Engine cannot be stopped 2 5 Starter motor does not rotate 1 2 3 4 5 6 7 23 Starter motor rotates slowly 1 2 Starter motor rotates normally but the engine does not start 8 9 10 11 Engine starts but stops again 8 9 10 11 12 Engine does not reach correct operating speed at full throttle 9 10 11 12 20 23 24 Engine runs roughly 10 11 High fuel consumption 12 14 23 Black...

Page 63: ...el 12 Insufficient air supply to the engine blocked air filter air leakage between the turbo and the engine intake manifold dirty compressor part in the turbocharger faulty turbo compressor poor engine compartment ventilation 13 Coolant temperature too high 14 Coolant temperature too low 15 Oil level too low 16 Coolant level too low 17 Air in coolant system 18 Faulty circulating pump 19 Defective ...

Page 64: ... messages and symbols may vary depending on the installation shown here are those seen on panels sold by Volvo Penta Warning Symbols Stimulus for power reduction warning A fault has been detected in the EATS system or The AdBlue DEF tank level has dropped to the first warning level P0002361 The warning symbol shines with a constant yellow light The EATS symbol shines with a constant light Major st...

Page 65: ...that the AdBlue DEF pump is connected that the SCR system electrical cables are connected that the NOx sensors are connected that the exhaust temperature sensor is connected that the temperature sensor for the AdBlue DEF is connected that there are no leaks in the exhaust system where substantial amount of solution can escape that the EGR valve is not stuck If the fault can not be remedied with an...

Page 66: ...uality alternative 1 standard A Engine rpm and torque B Time axis 1 A fault is detected and the warning lamp lights up 2 After 60 minutes engine speed drops to idle Ramp down takes around 10 minutes 3 If the fault is not remedied the engine will run at full power for 60 minutes after the first restart and then drop to idle 4 Depending on the installation it is possible to manually override the sys...

Page 67: ...on it is possible to manually override the system action and run the engine at full power for 30 minutes Engine will speed again drop to idle service tools are required to reset the system 5 If the fault is not remedied the engine will run at full power for 60 minutes after the first restart and then drop to idle 6 After the second restart the engine will run at full power for 60 minutes Engine wi...

Page 68: ...alternative 2 1 A fault is detected and the warning lamp lights up 2 After 60 minutes the warning lamp will flash 3 After a further 30 minutes engine speed drops to idle 4 If the fault is not remedied the engine will run at idle after restart 5 When the fault is remedied the engine will revert to full power 6 Depending on the installation it is possible to manually override the system action and r...

Page 69: ...A fault is detected and the warning lamp lights up 2 If the fault is not remedied after 3 5 hours engine torque will drop to 75 Ramp down takes around 1 minute The warning lamp flashes 3 After 27 minutes the engine will drop to idle with a 50 torque reduction Ramp down takes around 3 minutes 4 Following re start the engine will run at idle with a 50 torque reduction DEF quality problems will requi...

Page 70: ...OM 2061 77 12 Aftertreatment reagent temperature in tank 3031 274 0 1 4 5 Aftertreatment reagent dosing valve 3051 90 11 NOx Sensor Outlet 3226 270 2 7 Aftertreatment reagent quality sensor 3360 123 2 6 9 12 13 AdBlue DEF dosage valve 3361 89 3 4 5 7 10 AdBlue DEF tank heating valve 3363 75 3 4 5 AdBlue DEF Quality 3364 351 10 Engine Throttle Actuator 3464 7 3 4 5 12 AdBlue DEF ECU EEPROM 3511 77 ...

Page 71: ...Speed 4374 87 0 1 10 Aftertreatment Reagent Direction Valve 4376 105 3 4 5 7 NOx monitoring failure 5246 46 0 15 16 Aftertreatment reagent Dosing system 5394 90 17 AdBlue DEF ECU main relay 520233 85 3 4 5 6 Fault Code Register 69 47711089 09 2018 AB VOLVO PENTA ...

Page 72: ...ng Up page 90 111 1 3 4 5 18 Engine Coolant Level Coolant Level Checking and Topping Up page 90 131 3 5 12 Engine Exhaust Back Pressure 158 0 1 2 System Voltage Battery Charging 172 4 5 Ambient Air Temperature Sensor 173 0 16 Exhaust Gas Temperature 175 0 3 4 5 16 Engine Oil Temperature Oil level checking and topping up page 82 190 0 16 Engine Speed 626 3 4 5 Preheat Relay 628 2 14 Program Memory ...

Page 73: ...510 3 4 Sensor Supply Voltage 2 5V DC 3511 3 4 Sensor Supply Voltage 3 5V DC 3519 3 4 5 Aftertreatment Reagent Tank Temperature 3520 4 5 12 Aftertreatment Reagent Quality 3521 14 Aftertreatment Reagent Quality 3532 4 5 12 Aftertreatment Reagent Tank Level 3597 3 4 ACM Supply Voltage 3598 3 4 ACM Supply Voltage 4334 4 5 Aftertreatment Reagent Pressure 4354 3 4 5 Aftertreatment Reagent Hose Heater 1...

Page 74: ...4 5 11 Engine Oil Pressure Before Filter 520688 0 3 4 5 16 Aftertreatment Exhaust Temperature Dry 520689 3 4 5 EGR A Volvo Compression Brake VCB Control Circuit 520690 3 5 EGR A Control Turbocharger Supercharger Wastegate Solenoid A 520691 14 Torque Speed Control 1 Received With Errors Counter or Checksum Fault Code Register 72 47711089 09 2018 AB VOLVO PENTA ...

Page 75: ...enance handbook can be found at www volvopenta com Extended service intervals The interval between engine oil changes may be extended in certain circumstances To determine whether the service interval may be extended Volvo Penta s conditions for extended service intervals must be met and an oil analysis performed Contact your Volvo Penta dealer for further information Where both operational and ca...

Page 76: ...t 1000 hours of operation Type A Service Every 1000 hours of operation Type B Service Every 2000 hours of operation Type C Service Every82000 hours of operation 1 Oil change intervals vary depending on oil grade and sulfur content of the fuel Refer to Oil recommendations 2 Change oil filters every time the oil is changed Maintenance Schedule 74 47711089 09 2018 AB VOLVO PENTA ...

Page 77: ...ww volvopenta com CAUTION Read through the safety advice before starting any work WARNING Care and maintenance work should be done with the engine stopped unless otherwise specified Stop the engine before opening or removing the engine hatch hood Make it impossible to start the engine by removing the start key and cutting the system voltage with the main switches When ordering service or spare par...

Page 78: ...il filler cap engine 4 Oil dipstick 5 Auxiliary Stop 6 Control Panel 7 Air Filter 8 Fuel Filter 9 Fuel pre filter with water separator 10 Control Unit EMS 11 Turbo 12 Starter motor 13 Oil filter 14 Coolant Filter Maintenance 76 47711089 09 2018 AB VOLVO PENTA ...

Page 79: ...tor 2 Emergency Stop Switch 3 Oil filler cap engine 4 Oil dipstick 5 Fuel Filter 6 Fuel pre filter with water separator 7 Control Unit EMS 8 Turbo 9 Starter motor 10 Oil filter Maintenance 77 47711089 09 2018 AB VOLVO PENTA ...

Page 80: ...m WARNING If an oil fuel or coolant leak is detected the cause must be investigated and the fault rectified before the engine is started IMPORTANT Washing with a power washer Never aim the water jet at radiators charge air cooler seals rubber hoses or electrical components Air Filter Check and Replace The engine is equipped with electronic air filter indication The control unit provides an output ...

Page 81: ...rotating components and hot surfaces IMPORTANT Always change a belt which looks worn or cracked Inspections must be carried out after operations while the belts are hot You should be able to depress the alternator belt and the drive belt about 3 4 mm between the pulleys The alternator belts and drive belts have automatic belt tensioners and do not need to be adjusted Check the condition of the dri...

Page 82: ...a 1 2 square wrench in the belt tensioner 1 Lift the wrench and remove the drive belt 5 Thread the drive belt round the fan and remove it 6 Check that the pulleys are clean and undamaged 7 Thread the new drive belt over the fan 8 Lift the 1 2 wrench and install the new drive belt 9 Install the belt guards 10 Install the fan guard and fan ring round the cooling fan 11 Start the engine and perform a...

Page 83: ...lt tensioner 2 down and install the new alternator drive belt 8 Lift the 1 2 wrench in the belt tensioner 1 and re install the water pump drive belt 9 Install the belt guards 10 Install the fan guard and fan ring round the cooling fan 11 Start the engine and perform a function check Lubrication System Oil change intervals may vary according to the lubrication oil grade fuel sulfur content and runn...

Page 84: ...dipstick when the engine is stopped and the OPERATING side when in operation The oil level must be inside the marked area on the dipstick Never fill above the maximum limit on the oil dipstick Only fill oil when the engine is stopped Only use Volvo Penta recommended oils refer to Technical Data page 109 The oil level sensor only measures the oil level when the ignition is switched to on not contin...

Page 85: ...that no leakage can occur 2 Pump the oil out or remove the bottom drain plug and drain the oil Collect all the old oil and old filters and hand them to a re cycling station for destruction 3 Remove the drain hose or install the bottom drain plug 4 Fill with engine oil For change volume please refer to Technical Data page 109 Maintenance 83 47711089 09 2018 AB VOLVO PENTA ...

Page 86: ...e protective rim 2 on the oil filter bracket 4 Put a thin layer of engine oil on the seal rings of the new oil filters 5 Install the new oil filters Tighten the two full flow filters on the right of the illustration 1 2 3 4 of a turn after they bottom Tighten the bypass filter 3 4 1 turn after it bottoms 6 Top up with engine oil start the engine and let it run for 20 30 seconds 7 Stop the engine c...

Page 87: ...ot cause fire IMPORTANT Always observe the greatest cleanliness during refueling and work on the fuel system Only use the grades of fuel recommended in the fuel specification Draining condensate fuel system 1 Put a collection vessel under the fuel filter to collect the condensate and fuel 2 Open the drain nipple 1 in the base of the fuel pre filter 3 Tighten the drain tap 1 when fuel without water...

Page 88: ...unctions or damage 1 Clean round the fuel filter 2 Remove the filter with a suitable filter remover Collect any spilled fuel in a collection vessel 3 Clean the filter mating surface on the filter bracket 4 Lubricate the seal with diesel fuel and install the new fuel filter Tighten the fuel filter in accordance with the instructions on the fuel filter 5 Where necessary bleed the fuel system refer t...

Page 89: ...n hole in the lower part is not blocked 5 Install a new seal on the lower part and lubricate the seal with diesel fuel Re install the lower part of the filter 6 Lubricate the seal with diesel fuel Screw the filter onto the filter bracket by hand until the rubber seal just touches the mating surface Then tighten a further half turn no more 7 Connect the cable to the water trap sensor 8 Where necess...

Page 90: ...ng the plastic handle 3 Vent the fuel system by pumping with the hand pump Air is vented to the tank via the fuel return pipe No breathing nipples need be opened 4 Lock the hand pump push down and twist the handle 5 Start the engine and allow it to idle fast for about 10 minutes 6 Perform a leakage and function check P0025497 Maintenance 88 47711089 09 2018 AB VOLVO PENTA ...

Page 91: ...ich in the worst case can cause engine breakdown Volvo Penta strongly recommend the use of our own coolants Volvo Penta Coolant VCS Ready Mixed or the concentrate Volvo Penta Coolant VCS which ensure the protection of the cooling system components from corrosion ageing swelling and cracking thereby ensuring optimal engine lifetime Over time the corrosion protection additives become less effective ...

Page 92: ...ut Filling a completely empty system NOTICE Mix the correct amount of coolant in advance to ensure that the cooling system is completely filled Refer to Technical Data Cooling System for the correct coolant volume Do not open the pressure cap 2 1 Check that all drain points are closed 2 Open filler cap 1 3 Fill with coolant so that the level is between the MIN and MAX marks Fill slowly to allow ai...

Page 93: ...ated under the radiator on the right side of the engine block 5 Check that all coolant drains out Deposits may be found inside the drain plug tap and need to be cleared away There is otherwise a risk that coolant could remain and cause damage due to freezing Check whether the installation has any further taps or plugs at the lowest points of the cooling water pipes 6 Shut any taps and check that t...

Page 94: ...er flushing for a long time cleaning can be done with coolant Otherwise continue as in item 8 below 4 Fill the cooling system with 15 20 mixture of concentrated coolant Use only Volvo Penta recommended concentrated coolant mixed with clean water 5 Drain the coolant after 1 2 days of operation Remove the filler cap and possibly the lower radiator hose to increase the speed of emptying To prevent su...

Page 95: ...up with Volvo Penta recommended coolant following the instructions in the chapters entitled Maintenance page 89 and Coolant Level Checking and Topping Up page 90 Maintenance 93 47711089 09 2018 AB VOLVO PENTA ...

Page 96: ...nnectors must be replaced immediately Do not try to clean with water or compressed air IMPORTANT Dirt dust oil greases detergents and any chemicals and natural products must be prevented from entering the Adblue DEF tank The system will be damaged if dust or dirt enters the tank clogging the filters in the dosing system Keep the tank clean at all times IMPORTANT Never start the engine if anything ...

Page 97: ...ed negatively and engine components risk damage Damage and costs arising from a failure to meet these requirements are not covered by Volvo Penta warranty obligations If AdBlue DEF is filled from a can or pump that lacks a stop function it is important to make sure the tank is not overfilled as the solution may leak out of the breather tube If the tank is overfilled and the solution in it freezes ...

Page 98: ...illing of AdBlue DEF in the diesel tank Mistaken filling of diesel in the AdBlue DEF tank The engine will not run at full power or will not run at all Injectors may be damaged Corrosion in the exhaust system between the turbocharger and aftertreatment system Expensive repairs The aftertreatment system may be seriously damaged The engine will no longer fulfill emission level requirements Expensive ...

Page 99: ...ne has been turned off before removing the urea solution hoses so that automatic drainage and depressurization of the EATS system can take place 1 Switch off the engine Disconnect the battery negative terminal 2 Remove the heater coil connector from the filter cover NOTICE Pull the connector straight out Maintenance 97 47711089 09 2018 AB VOLVO PENTA ...

Page 100: ...ump unit Remove the filter 3 NOTICE If the filter has been loosened it has to be fully removed even if it is to be reused before reinstalling it again 6 Install a new O ring 2 in the new filter cover Install a new filter with the filter cover Install filter and cover together into the pump Tighten the filter cover using a torque wrench NOTICE Check that the drain valve is tightened 7 Reinstall the...

Page 101: ...straight 9 Connect the battery negative terminal 10 Start the engine and check that there are no leaks 11 Delete any fault codes refer to Diagnostic Function 12 NOTICE Take care of equipment and surplus urea solution and leave them at a re cycling station for destruction p0013223 Maintenance 99 47711089 09 2018 AB VOLVO PENTA ...

Page 102: ...has stopped running as it usually performs automatic emptying of the AdBlue DEF hoses 2 Disconnect the battery negative terminal 3 Place a collection vessel under the filter cover NOTICE Use approved safety equipment and collection vessel 4 Undo the filter cover P0019364 P0019389 Maintenance 100 47711089 09 2018 AB VOLVO PENTA ...

Page 103: ... pull out the filter by first pressing it into the filter hole until it clicks 6 Pull out the filter 7 Install the new filter 1 Install the rubber gasket 2 Screw on the filter cover 3 P0019390 P0019391 Maintenance 101 47711089 09 2018 AB VOLVO PENTA ...

Page 104: ... Ibf ft 9 Reconnect the battery negative terminal 10 Start the engine Check for leaks check function 11 Delete any fault codes NOTICE Care for equipment and the remaining AdBlue DEF P0019392 P0019365 p0013225 Maintenance 102 47711089 09 2018 AB VOLVO PENTA ...

Page 105: ...never be switched off before the engine has stopped If the circuit between the alternator and the battery is disconnected when the engine is running the alternator and electronics may be damaged For the same reason the charging circuits must never be re connected with the engine running Fuses The engine is equipped with a 10 A circuit breaker which cuts the current if overloaded The circuit breake...

Page 106: ...attery manufacture s recommendation and instruction when replacing and charging batteries Depending on battery type the instructions for maintenance and charging may vary Modern batteries are normally maintenance free but there are some actions that are recommended to increase the battery service life and avoid accidents Keep the batteries clean and dry Contamination and oxide on the batteries and...

Page 107: ...d WARNING Never confuse the positive and negative poles on the batteries Risk of arcing and explosion Disconnecting A 1 Untighten the nut and remove the cable black 2 Untighten the nut and remove the cable red Remove the battery Connecting B Place the new battery 1 Connect the cable red to the pole on the battery and tighten the nut 2 Connect the cable black to the pole on the battery and tighten ...

Page 108: ...als rubber hoses or electrical components For up to 8 month s stoppage Change the oil and oil filter on the engine then run the engine until warm More than 8 month s stoppage Conserve the lubrication and fuel systems with conservation oil Refer to the section Conservation of the lubrication and fuel systems for more than 8 months stoppage Make sure the coolant has adequate antifreeze properties To...

Page 109: ...o load Check that no oil fuel or coolant leakage occurs Fill the AdBlue DEF tank The solution must fulfill ISO 22241 standards Conservation of the lubrication and fuel systems for more than 8 months stoppage Drain the engine oil and fill up with conservation oil to just over the MIN marking on the dipstick Connect the fuel suction and return hoses to a 1 3 full jerrican containing conservation oil...

Page 110: ...ower Pac 1790 kg 3946 lb Firing order 1 5 3 6 2 4 Compression ratio 18 1 1 Idling speed 600 1200 Type designation TAD1371 72 73 74 75VE Power prime stand by Refer to the sales literature Torque Prime Standby Refer to the sales literature No of cylinders 6 Bore 131 mm 5 16 inch Stroke 158 mm 6 22 inch Displacement 12 78 dm3 780 in3 Weight wet Engine 1325 kg 2921 lb Weight wet Power Pac 1790 kg 3946...

Page 111: ...e oil pump Type Gear driven Oil recommendations Engine Oil quality Oil change interval reached first in operation TAD1360 65VE VDS 3 VDS 2 600 hours or 12 months TAD1371 75VE VDS 3 VDS 4 5 1000 hours or 12 months VDS Volvo Drain Specification Viscosity Select the viscosity according to the table The temperature values refer to stable ambient temperatures SAE 5W 30 refers to synthetic or semi synth...

Page 112: ... and function of the fuel injection equipment Max lubricity wsd 1 4 for JIS K 2204 460 μm Sufficient fuel lubricity is essential to protect the fuel injection system against excessive wear Restrictions for other diesel fuels Volvo Penta also approves the use of other diesel fuels as long as the here specified restrictions are followed However Volvo Penta does not guarantee compliance with emission...

Page 113: ...l fuels that complies with standard EN 15940 The fuel guarantees compliance with emission legislation and fulfills the expected lifetime as long as the service requirements are followed Volvo Penta also approves the use of fuel blends between these paraffinic fuels and diesel fuels that comply with the quality requirements Service requirements When shifting from diesel fuel to paraffinic fuel the ...

Page 114: ... 2 psi Coolant Volume engine 20 liters 5 28 US gal Volume engine with standard radiator and hoses Radiator standard 44 liters 11 6 US gal Radiator HD Heavy Duty 58 liters 15 3 US gal Thermostat Qty 1 pc Opening temperature 82 C 180 F Technical Data 112 47711089 09 2018 AB VOLVO PENTA ...

Page 115: ...pecified water requirements refer to Water Quality page 113 NOTICE Always use Ready Mixed coolant if water quality cannot be determined or if it does not fulfill ASTM D4985 NOTICE Never mix more than 60 concentrated coolant with water A greater concentration provides reduced cooling effect with the risk for overheating and reduced freeze protection Water Quality ASTM D4985 Total solid particles 34...

Page 116: ...ctrical System System voltage 24V Alternator voltage max current 28V 80A power app 2200W Battery capacity 2 pcs series connected 12 V max 220 Ah Battery electrolyte specific gravity at 25 C fully charged battery 1 28 g cm3 1 24 g cm3 battery recharged at 1 20 g cm3 1 20 g cm3 Note Applies to batteries with tropical acid Technical Data 114 47711089 09 2018 AB VOLVO PENTA ...

Page 117: ... E Serial number F Power kW G Engine speed rpm H Country of manufacturing A Label part number B Engine Family C Power Category D Date of Manufacture mm yy E Model Year F Generator for GenSets and other applications G Constant Speed used in constant speed applications only H Exhaust Emission Control System Technical Data 115 47711089 09 2018 AB VOLVO PENTA ...

Page 118: ...1 7 4 and 1 7 4 3 The relevant technical documentation is compiled as described in part B of Annex VII Relevant information concerning the partially completed machinery will be provided in suitable form upon justified requests from competent national authorities The individual authorized to compile the relevant technical documentation is the signer of this declaration The harmonizing standards app...

Page 119: ...103 114 Emission Aftertreatment System 19 EMS Engine Management System 22 Engine Fuel Filter Replacement 86 Engine Oil Change 83 Engine General 78 Engines 21 108 Environmental care 17 Erasing fault codes 58 Excessive strain on a product and components 16 F Fault Tracing 60 Filling AdBlue DEF 94 Fuel Pre filter Change 87 Fuel System 85 110 Fuel system bleeding 88 Fuel oils and coolant 15 I Identifi...

Page 120: ......

Page 121: ...nternet yhteyttä ota yhteys lähimpään Volvo Pen ta jälleenmyyjään Este Manual do Operador pode ser encomendad em idi omas diferentes isento de custos até 12 meses após entrega via internet http manual volvopenta com coupon Se não for possível aceder à internet contacte o seu concessi onário Volvo Penta To παρόν Βιβλίο Χρήσης μπορεί να παραγγελθεί δωρεάν σε άλλη γλώσσα μέχρι 12 μήνες μετά την παράδ...

Page 122: ...AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com 47711089 English 09 2018 ...

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