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Volvo Penta TAD1340VE, Operator'S Manual

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Volvo Penta TAD1340VE Operator'S Manual Download Page 64

TWD1643GE, TWD1644GE, TWD1645GE,
TWD1652GE, TWD1653GE

1 Expansion tanks

2 Oil filler cap, engine

3 Control Unit, EMS

4 Auxiliary Stop

5 Air Filter

6 Charge air cooler (High-Pressure Turbo)

7 Crankcase ventilation

8 Fuel filter, with fuel pressure monitor

9 Fuel prefilter with water monitor

10 Oil dipstick

11 Air filter indicator

12 Low-Pressure Turbo

13 High-Pressure Turbo

14 Charge air cooler (Low-Pressure Turbo)

15 Oil filter

1

9

5

4

3

2

6

7

8

10

12

11

14

13

P0020401

15

 

Maintenance

62

47711296 01-2019  © AB VOLVO PENTA

Summary of Contents for TAD1340VE

Page 1: ...Operator s manual 16L TP 6662 1 19d ...

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: ...ontrol Unit 38 Starting in Extreme Cold 39 Never Use Start Spray 40 Starting Using Auxiliary Batteries 40 Operation 41 Reading the Instruments 41 Alarms 41 Maneuvering 41 Operation at low load 41 Engine Shutdown 43 Before Engine Shutdown 43 Stop the Engine 43 Auxiliary Stop 44 After Engine Shutdown 45 Fault handling 46 Diagnostic Function 46 DCU Display Control unit 47 DCU II Display Control Unit ...

Page 4: ...r Change 75 Fuel system bleeding 76 Cooling System 77 Coolant Level Checking and Topping Up 78 Coolant Draining 80 Charge Air Cooler External Cleaning 80 Cooling System Cleaning 81 Cooling air filter 83 Electrical System 84 Main switch 84 Electrical Connections 84 Battery 85 Storage 87 Technical Data 89 Engines 89 Lubrication System 92 Viscosity 92 Fuel System 93 Cooling System 95 Coolant Mixing 9...

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 your nearest authorized Volvo Penta dealer for assistance It is possible to buy additional literature about you...

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: ...nd 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 running or by disconnecting the battery cables The alternator and electronics could be damaged Avoid damage to the engine control module and other electronics IMPORTANT Switch off the main switch before con...

Page 12: ...ap is on There is a risk that hot oil can spray out Refueling WARNING There is always a risk of fire and explosion during refueling Smoking is forbidden and the engine must be stopped Proper fuel quality IMPORTANT Always use the fuel recommended by Volvo Penta See Technical Data in Operator s Manual Other fuel can damage the engine Wrong fuel quality can also lead to higher service costs WARNING R...

Page 13: ...us injuries Do not touch the connections during start attempts Sparking hazard Do not lean over batteries Correct polarity of the batteries IMPORTANT Make sure that the positive and negative battery cables are correctly connected to the corresponding battery terminals Wrong connection may cause severe damage to electrical equipment Risks of electrolyte in batteries WARNING Always wear protective g...

Page 14: ... Cleanliness for sensitive components IMPORTANT Observe 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 P0024486 Safety Information 12 47711296 01 2019 AB VOLVO PENTA ...

Page 15: ...ual 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 subject to the conditions compiled in the Warranty Information AB Volvo Penta s liabi...

Page 16: ...cked 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 filters at the specified maintenance i...

Page 17: ...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 18: ...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 19: ...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 20: ...wnload the dealer locator app to your smartphone Volvo Penta Action Service Our global dealer network your first line of contact is backed up by Volvo Penta Action Service a phone based breakdown and support service providing assistance 24 hours a day every day of the year How it works A dedicated operator will support you all the way through your case and keep you updated on status and progress W...

Page 21: ...TWD1644GE TWD1645GE TWD1652GE TWD1653GE These are in line directly injected 6 cylinder industrial diesel engines The engines are all equipped with electronically controlled fuel management turbocharger charge air cooler thermostatically controlled cooling systems and electronic speed control TAD1650VE TAD1650VE B TAD1651VE TWD1652GE TWD1653GE TAD1650GE and TAD1651GE are equipped with EGR Exhaust G...

Page 22: ...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 23: ...icates with the engine control unit The DCU has several 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 illu...

Page 24: ... 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 22 47711296 01 2019 AB VOLVO PENTA ...

Page 25: ...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 26: ...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 27: ...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 28: ...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 29: ...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 30: ...lation and engine model 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 dow...

Page 31: ...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 32: ...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 33: ...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 34: ... heard the system has discovered a malfunction 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 Cont...

Page 35: ...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 36: ...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 34 47711296 01 2019 AB VOLVO PENTA ...

Page 37: ...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 38: ...ed CAN link All data related to instruments indication lamps connectors and potentiometers is controlled by this link The slow link manages diagnostic information for flashing codes etc Easy Link Instruments 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 Oi...

Page 39: ... 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 73 Check the coolant level and that the radiator is not blocked externally Refer to Coolant Level Checking and Topping Up page 78 and Charge Air Cooler External Cleaning page 80 WARNING Do not open the coolant fi...

Page 40: ...AD1650GE TAD1650VE TAD1651GE TWD1643GE TWD1652GE TWD1653GE 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 Lea...

Page 41: ...tation in the fuel system At extremely low temperatures we recommend 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 92 Synthetic lubricants are able to handle a wider temperature range than mineral based lubricants Pre heat the coolant with a separately installed electric engi...

Page 42: ...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 43: ...ation at low load Avoid long term operation at idle or at low load It takes a long time for the engine to reach working temperature resulting in high viscosity of the oil and large clearances in the engine mechanics In cold climate it takes even longer The combustion temperature and cylinder pressure can become so low that an effective combustion cannot be ensured At these conditions unburned fuel...

Page 44: ...alfunctions caused by operation at low load follow these points as a complement to normal maintenance Run in the engine as soon as possible Load the engine so it reaches working temperature as soon as possible Turn off the engine instead of running on idle for longer periods Avoid load levels below 20 as constant operation If the engine is regularly tested without load limit the duration of the op...

Page 45: ... 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 Engine TAD1640VE B TAD1641VE B TAD1642VE B TAD1643VE TAD1650GE TAD1650VE TAD1651GE ...

Page 46: ...ation of the extra stop refer to Maintenance page 60 WARNING Working with or approaching a running engine is a safety risk Watch out for rotating components and hot surfaces Engine Shutdown 44 47711296 01 2019 AB VOLVO PENTA ...

Page 47: ...e 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 87 IMPORTANT If there is a risk of freezing the coolant in the cooling system must have adequate antifreeze protection Refer to Maintenance page 77 IMPORTANT A poorly charged battery can freeze and burst ...

Page 48: ...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 49: ...D1650VE B TAD1651GE TWD1644GE TWD1645GE 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 concerne...

Page 50: ... the engine 3 Press the SEL button to get to the 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 nec...

Page 51: ...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 fault code reappears all fault codes have been read off If the diagnostics button is pressed after the fault has been rectified and the fault codes have been erased code 1 1 No fault will be displayed Easy Li...

Page 52: ...ed 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 to be acknowledged again Fault handling 50 47711296 01 2019 AB VOLVO PENTA ...

Page 53: ...can not be stopped 2 5 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 speed at full throttle 9 10 11 12 13 21 25 26 Engine runs roughly 10 11 High fuel consumption 12 13 15 25 Black exhaust smoke 12 13 Blue or white e...

Page 54: ...ter air leakage between the turbo and the engine s intake manifold dirty compressor part in the turbocharger faulty turbo compressor poor engine room ventilation 14 Coolant temperature too high 15 Coolant temperature too low 16 Oil level too low 17 Coolant level too low 18 Air in the coolant system 19 Faulty circulation pump 20 Defective thermostat 21 Blocked charge air cooler 22 Oil level too hig...

Page 55: ...t temperature 105 105 3 2 6 2 0 4 5 16 Boost pressure 106 106 3 4 3 5 0 3 5 16 Air filter pressure 107 107 5 5 5 5 0 3 4 5 Ambient air pressure 108 108 2 3 4 Coolant Temperature Coolant Level Checking and Topping Up page 78 110 110 3 3 6 1 0 4 5 16 Coolant Level Coolant Level Checking and Topping Up page 78 111 111 2 3 2 2 1 3 5 Crankcase pressure 153 153 7 8 7 7 0 2 3 5 Battery voltage Battery Ch...

Page 56: ...4 5 12 Starter motor relay 677 39 4 6 3 4 5 Injection Control Pressure Regulator 679 42 8 3 3 4 5 6 Pressure Release Valve 679 97 8 3 0 7 11 14 Starter element 729 70 8 6 3 4 5 Stop Input EMS 970 6 4 8 EMS 4 Fan speed 975 26 3 Compression break 1072 122 1 3 4 5 5 V sensor supply 1079 232 9 3 3 4 5 V sensor supply 2 1080 211 9 3 3 4 ECU temperature 1136 55 8 4 16 Exhaust gas temperature 1184 173 4 ...

Page 57: ...E B TAD1642VE B TAD1643VE B TAD1650VE B TAD1651VE TWD1643GE TWD1644GE TWD1645GE TWD1652GE TWD1653GE Fault codes engine SPN Component FMI 20 Coolant Water Pressure 1 3 5 18 51 Engine Throttle position cold 3 5 7 12 13 91 Accelerator Pedal position 0 9 19 94 Fuel Delivery Pressure Maintenance page 73 3 5 12 18 97 Water in fuel indicator Draining condensate fuel system page 73 0 4 12 98 Engine Oil Le...

Page 58: ...njector Cylinder 3 3 5 654 Fuel Injector Cylinder 4 3 5 655 Fuel Injector Cylinder 5 3 5 656 Fuel Injector Cylinder 6 3 5 677 Starter motor relay 3 4 5 6 679 Injection Control Pressure Regulator 3 4 5 6 679 Pressure Release Valve 0 7 11 14 729 Preheater 5 6 7 12 970 Engine stop switch 3 4 5 11 14 1136 ECU temperature 16 1184 Exhaust gas temperature 0 4 5 16 1188 Wastegate Valve 3 4 5 1485 ECM Main...

Page 59: ...bnet 9 520567 Aftertreatment Exhaust Temperature Wet 0 3 4 5 16 520570 Engine Oil Pressure Before Filter 3 4 5 11 520688 Aftertreatment Exhaust Temperature Dry 0 3 4 5 16 520689 EGR A Volvo Compression Brake VCB Control Circuit 3 4 5 520690 EGR A Control Turbocharger Supercharger Wastegate Solenoid A 3 5 520691 Torque Speed Control 1 Received With Errors Counter or Checksum 14 Fault Code Register ...

Page 60: ...and Maintenance 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 S1 S2 S3 Special Int...

Page 61: ...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 62: ...entation TAD1643VE B 1 Control unit EMS 2 Fuel pre filter with water separator 3 Fuel filter 4 Oil dipstick 5 Oil filler cap 6 Alternator 7 Oil filter 8 Turbo Maintenance 60 47711296 01 2019 AB VOLVO PENTA ...

Page 63: ... B TAD1643VE 1 AC generator 2 Control unit EMS 2 3 Air Filter 4 Oil filter 5 Oil dipstick 6 Fuel filter with fuel pressure monitor 7 Fuel prefilter with water monitor 8 Expansion tank 9 Radiator 10 Starter motor Maintenance 47711296 01 2019 AB VOLVO PENTA 61 ...

Page 64: ...ooler High Pressure Turbo 7 Crankcase ventilation 8 Fuel filter with fuel pressure monitor 9 Fuel prefilter with water monitor 10 Oil dipstick 11 Air filter indicator 12 Low Pressure Turbo 13 High Pressure Turbo 14 Charge air cooler Low Pressure Turbo 15 Oil filter 1 9 5 4 3 2 6 7 8 10 12 11 14 13 P0020401 15 Maintenance 62 47711296 01 2019 AB VOLVO PENTA ...

Page 65: ...AD1651GE 1 Control unit EMS 2 Oil filler 3 Oil dipstick 4 Fuel filter to be installed separately 5 Fuel pre filter with water monitor to be installed separately 6 Starter motor Maintenance 47711296 01 2019 AB VOLVO PENTA 63 ...

Page 66: ... Control Unit EMS 2 Auxiliary stop 3 Alternator 4 Oil filler cap engine 5 Oil dipstick 6 Fuel Filter 7 Fuel pre filter with water separator 8 Turbo 9 Starter motor 10 Oil filter Maintenance 64 47711296 01 2019 AB VOLVO PENTA ...

Page 67: ...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 68: ...ing 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 drive be...

Page 69: ...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 do a function check 1 P 2086 000 TAD1640GE B TAD1641GE B TAD1642GE B TAD1650GE TAD1651GE TAD1640VE B TAD1641VE B TAD1642VE B TAD1643VE TAD1643VE B ...

Page 70: ...move the alternator belts 6 Check that the pulleys are clean and undamaged 7 Press the 1 2 wrench in the belt tensioner 2 down and install the new alternator drive belt 8 Lift the 1 2 wrench in the belt tensioner 2 and install the new 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 do a function check 1 2 P 2084 00...

Page 71: ...urther information NOTICE Oil change intervals must never exceed a period of 12 months Oil change intervals may vary according to the lubrication oil grade fuel sulfur content and running conditions Refer to Oil recommendations The oil change interval may under certain conditions be increased To see if the engine complies Volvo Penta oil analysis needs to be performed Contact your Volvo Penta deal...

Page 72: ... 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 92 The oil level sensor only measures the oil level when the ignition is switched to on not contin...

Page 73: ... 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 92 Maintenance 47711296 01 2019 AB VOLVO PENTA 71 ...

Page 74: ... are left behind Carefully clean round the inside of the protective rim 2 on the oil filter bracket 4 Put a thin layer of engine oil on the seal rings of the new fuel filters 5 Install the new oil filters Tighten the filters 1 turn after they touch 6 Top up with engine oil start the engine and let it run for 20 30 seconds 7 Turn off the engine check the oil level and top up as required 8 Check sea...

Page 75: ...ays 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 NOTICE Put a collection vessel under the fuel filter tocollect the condensate and fuel 1 Open the drain nipple in the base of the fuel pre filter 2 Tighten the drain tap when fuel without water starts to run out P0002101...

Page 76: ...hat contamination could get into the system and cause malfunctions 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 f...

Page 77: ... 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 If necessary vent ...

Page 78: ...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 76 47711296 01 2019 AB VOLVO PENTA ...

Page 79: ...hich 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 80: ...other Filling of coolant must be performed with the engine stopped Fill up slowly to allow the air to flow out Check the coolant level daily before start TWD16 1 Open the filler caps 1 2 Check that the coolant reaches the MAX mark on the sight glass 2 Top up with coolant as required 3 Close the filler caps TAD16 1 Open only the filler cap 1 Do not open the pressure cap 2 2 Check that the coolant l...

Page 81: ...D16 Open the caps to both the expansion tank 1 and the radiator 2 Fill the expansion tank so that the coolant reaches the MAX mark on the sight glass Close the filler caps TAD16 Open only the filler cap 1 Fill the expansion tank so that the coolant level is between the MIN and MAX marks Close the filler cap 3 Bleed the system at the bleeding nipple 3 4 Start the engine when the coolant system i co...

Page 82: ...ain nipples are situated under the radiator on the right side of the engine block 4 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 the coolant could remain and cause frost damage Check whether the installation has any further taps or plugs at the lowest points of the cooling water pipes 5 Close any taps a...

Page 83: ...r 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 sus...

Page 84: ...up with Volvo Penta recommended coolant following the instructions in the chapters entitled Maintenance page 77 and Coolant Level Checking and Topping Up page 78 Maintenance 82 47711296 01 2019 AB VOLVO PENTA ...

Page 85: ...ape around the fan cover guard as in fig 3b and 3c Removal and cleaning 1 Remove the cooling filter 2 Brush away any heavy dirt with a soft brush 3 Rinse the filter with water NOTICE If a cleaning agent is necessary an eco friendly degreaser e g coconut oil based must be used as a first choice Alternatively use a paraffin fraction as a second choice Spray on the degreaser or apply it using a spong...

Page 86: ...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 87: ...battery 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 an...

Page 88: ...ed 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 89: ...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 90: ... with no 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 conservat...

Page 91: ...g lb 1550 3417 1550 3417 1550 3417 1770 3902 Firing order 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 Compression ratio 17 5 1 16 5 1 16 5 1 16 5 1 Low idle r min 900 900 900 900 Type designation TWD1644GE TWD1645GE Power Refer to the sales literature Torque Refer to the sales literature No of cylinders 6 6 Bore mm inch 144 5 67 144 5 67 Stroke mm inch 165 6 50 165 6 50 Displacement liter inch...

Page 92: ... 3 6 2 4 Compression ratio 16 5 1 16 5 1 16 5 1 16 5 1 Low idle r min 900 900 900 900 Type designation TAD1640VE B TAD1641VE B TAD1642VE B TAD1643VE Power Refer to the sales literature Torque Refer to the sales literature No of cylinders 6 6 6 6 Bore mm inch 144 5 67 144 5 67 144 5 67 144 5 67 Stroke mm inch 165 6 50 165 6 50 165 6 50 165 6 50 Displacement liter inch3 16 12 983 9 16 12 983 9 16 12...

Page 93: ... 67 Stroke mm inch 165 6 50 165 6 50 165 6 50 165 6 50 Displacement liter inch3 16 12 983 9 16 12 983 9 16 12 983 9 16 12 983 9 Weight dry kg lb 1425 3142 Weight wet kg lb 1440 3175 1395 3075 1395 3075 Firing order 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 Compression ratio 17 0 1 18 0 1 17 0 1 17 0 1 Low idle r min 600 900 600 900 600 900 600 900 Technical Data 47711296 01 2019 AB VOLVO PEN...

Page 94: ...pump Type Gear driven Oil recommendations Type designation Oil quality Oil change interval reached first in operation TAD1640GE B TAD1641GE B TAD1642GE B TWD1643GE TWD1644GE TWD1645GE TAD1650GE TAD1651GE TWD1652GE TWD1653GE TAD1640VE B TAD1641VE B TAD1642VE B TAD1643VE TAD1650VE VDS 3 VDS 2 600 hours or 12 months TAD1650VE B TAD1651VE TAD1643VE B VDS 3 VDS 4 5 500 hours or 12 months VDS Volvo Drai...

Page 95: ... the durability 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 complianc...

Page 96: ...nd therefore increase the risk of bacterial growth in the fuel This may lead to blocked fuel filters Engine not consuming a full fuel tank within 4 weeks must not use biodiesel Higher levels of biodiesel up to B30 may be used with restrictions Fuel according to EN 16709 or ASTM D7467 or relevant local fuel standards that fulfill mentioned biodiesel fuel standards must be used Volvo Penta does not ...

Page 97: ... B TAD1650VE B Engine with standard radiator and hoses Pusher system 61 liters 16 1 US gal Engine with standard radiator and hoses Puller system 54 liters 14 3 US gal Engine with HD radiator and hoses Pusher and puller system 56 liters 14 8 US gal TWD1643GE TWD1644GE TWD1645GE TWD1652GE TAD1653GE Engine circuit Engine with radiator hoses and expansion tank Pusher system 86 liters 22 7 US gal Charg...

Page 98: ...specified water requirements refer to Water Quality page 96 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 99: ...e density 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 NOTICE Applies to batteries with tropical acid Electrical platform EMS 2 0 TAD1643VE TWD1643GE EMS 2 2 TAD1640VE B TAD1641VE B TAD1642VE B TAD1650VE TAD1650GE TAD1651GE TWD1652GE TWD1653GE EMS 2 3 TAD1643VE B TWD1644GE TWD1645GE TAD1650VE B TAD1651VE EMS 2 4 TAD1640GE B TAD1641GE B TAD1642GE B ...

Page 100: ...laced on the valve cover A Chassis ID B Serial number A Label part number B Product designation C Specification number D Chassis ID E Serial number F Power kW G Engine speed rpm H Country of manufacturing Technical Data 98 47711296 01 2019 AB VOLVO PENTA ...

Page 101: ...1 7 1 2 1 7 4 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 harmonized ...

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Page 103: ...ments 36 49 Electrical Connections 84 Electrical System 84 97 EMS Engine Management System 20 Engine Fuel Filter Replacement 74 Engine Oil Change 71 Engine General 65 Engines 19 89 Environmental care 16 Erasing fault codes 50 Excessive strain on a product and components 15 F Fault Tracing 51 Fuel Pre filter Change 75 Fuel System 73 93 Fuel system bleeding 76 Fuel oils and coolant 14 I Identificati...

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Page 105: ...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 106: ...AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com 47711296 English 01 2019 ...

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