Volvo Penta TAD734GE Manual Download Page 4 | Manualshive

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Presentation

Engines

This Operator's Manual contains descriptions and
maintenance instructions for TAD940GE, TAD941GE,
TAD940VE, TAD941VE, TAD942VE, TAD943VE,
TAD950VE, TAD951VE and TAD952VE industrial die-
sel engines.

They are 6-cylinder in-line engines with direct injection.
All engines are equipped with electronically controlled
fuel management (EMS 2), turbocharger, charge air
cooler, thermostatically controlled cooling systems
and electronic speed control.

TAD950VE, TAD951VE have TAD952VE are also
equipped with internal EGR (Exhaust Gas Recircula-
tion).

47702660 03-2013 © AB VOLVO PENTA

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Summary of Contents for TAD734GE

Page 1: ...he crankshaft Deep front oil sump Oil filler on top Oil dipstick short in front Integrated full flow oil cooler side mounted Fuel system Common rail Gear driven fuel feed pump Six hole fuel injection nozzles Electronic governor Fuel prefilter with water separator Fine fuel filter of cartridge insert type Intake and exhaust system Connection flange for exhaust line Waste gate turbo charger centre l...

Page 2: ...204 0 331 205 0 332 Max Standby Power g kWh lb hph 25 247 0 400 259 0 420 50 235 0 381 239 0 387 75 217 0 352 225 0 365 100 205 0 332 207 0 336 Intake and exhaust system 1500 rpm 1800 rpm Air consumption at 27 C m min cfm Prime Power 16 1 569 18 3 646 Max Standby Power 16 3 576 18 9 667 Max allowable air intake restriction kPa In wc 3 0 12 0 3 0 12 0 Heat rejection to exhaust kW BTU min at Prime P...

Page 3: ...OPERATOR S MANUAL 9 Liter EMS 2 Volvo TAD734GE ...

Page 4: ...trial die sel engines They are 6 cylinder in line engines with direct injection All engines are equipped with electronically controlled fuel management EMS 2 turbocharger charge air cooler thermostatically controlled cooling systems and electronic speed control TAD950VE TAD951VE have TAD952VE are also equipped with internal EGR Exhaust Gas Recircula tion 47702660 03 2013 AB VOLVO PENTA 9 ...

Page 5: ...s function The purpose of the diagnostic function is to detect and locate any malfunctions in the EMS system to protect the engine and to ensure operation in the event of serious malfunction If a malfunction is detected it is announced by warn ing lamps a flashing diagnostic lamp or in plain lan guage on the instrument panel depending on the equipment used If a fault code is provided as a flash in...

Page 6: ...ICE 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 language can be changed however refer to the Setup menu 1 2 3 4 5 6 7 8 9 10 P0002062 Start When the DCU panel is started the Engine Data menu is displayed press ESC to come to the main menu 1 LED display 6 ON OF...

Page 7: ...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 8: ...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 9: ...he 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 s...

Page 10: ...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 11: ...htness setting Information shows the data for the engine and DCU Engine hardware Id engine control unit part num ber 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 12: ...isplay will work but may act in an unex pected 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 Graph it ...

Page 13: ...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 14: ...p and down 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 Fault Handling page 34 Instruments and Controls 47702660 03 2013 AB VOLVO PENTA 19 ...

Page 15: ...DEMO switches the DEMO mode ON OFF RESTORE DEAFAULTS reset all configuration to default values COM VIEWER displays latest message on com munication 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 s...

Page 16: ...ctors and poten tiometers is controlled by this link The slow link manages diagnostic information for flash ing 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 diag nostic button is pressed Coolant temperature Oil pressure Oil temperature Battery voltage Alarm panel Turbo pr...

Page 17: ...pstick For filling refer to Oil level checking and topping up Open the fuel valves Check the fuel pre filter refer to Draining conden sate fuel system page 51 Check the coolant level and that the radiator is not blocked externally Refer to Coolant Level Check ing and Topping Up page 54 and Charge Air Cooler External Cleaning page 55 WARNING Do not open the coolant filler cap when the engine is war...

Page 18: ...CU Display Control Unit With pre heating 1 Depress the ON OFF button 6 2 Press the SEL button 8 to come to the main menu 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 firs...

Page 19: ...m chapter Synthetic lubri cants are able to manage a wider temperature range than mineral based lubricants Pre heat the coolant with a separately installed ele tric engine heater In extreme cases a diesel burn ing engine heater may be needed Ask your Volvo Penta dealer for advice Make sure that the cooling system is filled with a glycol mixture Please refer to the Maintenance cooling system chapte...

Page 20: ...umper cable to the auxili ary 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 connections during the start attempt Risk of arcing Do not bend over any of the...

Page 21: ...st every 24 hours Refer to Oil level checking and topping up Check all instruments directly after starting and then regularly during operation NOTICE On engines in continuous operation the lubrication oil level must be checked at least every 24 hours Refer to Oil level checking and topping up Alarms If the EMS 2 system receives abnormal signals from the engine the control unit generates fault code...

Page 22: ... become so low that complete combustion cannot be ensured resulting in possible fuel dilution of lubricating oil and eventually leakage from the exhaust manifold If the following points are done as a complement to normal maintenance there will be no risk of malfunc tions caused by operation at low load Reduce operation at low load to a minimum If the engine is regularly test run without load once ...

Page 23: ...ch if possible Depress the STOP button 5 After Engine Shutdown 1 Check the engine and engine bay for leakage 2 Turn off the main switches before any long stop page 3 Carry out maintenance in accordance with the schedule For longer breaks in operation During longer breaks in operation the engine must be warmed up at least once every two weeks This pre vents corrosion attacks in the engine If you ex...

Page 24: ...e extra stop please refer to Location of Sensors page 43 WARNING Working with or going close to a running engine is a safety risk Watch out for rotating components and hot surfaces Engine Shutdown 47702660 03 2013 AB VOLVO PENTA 29 ...

Page 25: ... Refer to Diagnostic Function Engine cannot 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 unevenly 10 11 High fuel consumption 12 13 15 25 Blac...

Page 26: ...lty unit injector 13 Insufficient air supply to engine blocked air filter air leakage between turbocharger and engine inlet manifold fouled compressor section in turbocharger faulty turbocharger poor engine bay 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...

Page 27: ...sturbance in the system this is reported with a fault code via the instruments The diagnostic function protects the engine and ensure continued operation by affecting the engine depend ing on the severity the engine is affected differently Depending on what instrumentation that is being used the fault message is shown in various ways fault codes can also be read out by VODIA All fault codes and fa...

Page 28: ...ins 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 fault ...

Page 29: ...s and the number of hours of operation when the fault occurred 4 Press ACK to acknowledge the fault code The dis play 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 three seconds to view SPN and FMI codes 7 Press ...

Page 30: ...the SEL button to get to the fault list The fault list shows hours of operation fault messages active non active faults 4 Look up the fault code in the Fault Code Register and take the necessary actions 5 Press ESC to leave the fault list NOTICE To get to the fault list when no fault codes are set press the SEL button and select Diagnos tics from the menu Fault Handling 47702660 03 2013 AB VOLVO P...

Page 31: ...splayed 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 NOTICE Power must be disconnected completely This means that fault that hasn t been corrected 1 are shown as active the active ...

Page 32: ...3 4 5 Ambient air pressure 108 108 2 3 4 Coolant Temperature Coolant Level Checking and Topping Up page 54 110 110 3 3 6 1 0 4 5 16 Coolant Level Coolant Level Checking and Topping Up page 54 111 111 2 3 2 2 1 3 5 Crankcase Pressure 153 153 7 8 7 7 0 2 3 5 Battery Voltage Battery Charging page 60 158 158 3 9 EMS 6 9 CIU 1 3 4 Injection control pressure 164 164 8 3 2 4 5 Ambient Air Temperature Sen...

Page 33: ...4 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 5V sensor supply 1079 232 9 3 3 4 5V sensor supply 2 1080 211 9 3 3 4 ECU temperature 1136 55 8 4 16 Exhaust Temperature 1184 173 4 9 1 9 0 4 5 16 Wastegate Valve 1188 32 3 4 5 SAE J1939 Data Link 1231 232 2 SAE J1939 Data Link 1231 229 9 Rail pressure system 1239 96 8 3 0 1 4 7 ...

Page 34: ...S 5 2 CIU Stop Input CIU 520195 6 5 3 CIU 4 Frequncy select input 113 Diagnostic request switch input 259 Oil pressure warning lamp status 260 4 1 Coolant level warning lamp status 261 4 5 Diagnostic lamp status 262 Run indication lamp status 263 4 3 Over speed indication lamp status 264 4 4 Coolant temperature warning lamp output 7 4 2 Fault Code Register 47702660 03 2013 AB VOLVO PENTA 39 ...

Page 35: ...ervice program FSI First Service Inspection C Clean S Special Service R Replace A F Type of service regular service L Lubrication I Inspection includes if necessary cleaning adjust ment lubrication and change FSI First Service Inspection After the first 100 200 Hours Fuel pre filter draining water contamination I Coolant Level I Drive Belts I Start and warm up engine Coolant oil fuel leakage I Ins...

Page 36: ...lter R Coolant filter if fitted Not at same time as coolant change R C Every 2000 Hours Valve clearance I D Every 2000 Hours At least every month 12 24 48 Turbo I Turbo Wastegate I Engine with Respect to Leakage I Engine hoses cables and clamps I Engine cleaning and painting I Air Filter Tank Breather R Air Filter Compressor R E Every 4000 hours At least every month 12 24 48 Belt Tensioner I Drive...

Page 37: ...uld 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 Read about security measures for maintenance and service in the chapter Safety Information page 3 before you begin Orientation 1 Alternator 2 Control uni...

Page 38: ...ture sennder 4 Auxiliary stop 12 Main fuse 5 Charge air pressure Intake manifold temperature 13 Preheater with preheater relay 6 Coolant temperature sensor 14 Camshaft sensor 7 Main relay 15 Flywheel sensor 8 Diagnosis connector 2 pin TAD940 43VE TAD940 941GE 6 pin TAD950 51VE TAD940 943GE VE TAD950 952VE P0015886 Maintenance 47702660 03 2013 AB VOLVO PENTA 43 ...

Page 39: ...NG If an oil fuel or coolant leak is detected the cause must be investigated and the fault rectified before the engine is started IMPORTANT Remember the following when 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 Change The engine is equipped with electronic air filter indica tion The control uni...

Page 40: ...or Belt Change IMPORTANT Always change a drive belt which appears worn or cracked 1 Disconnect the main switch es and check that the engine is not connected to system voltage 2 Remove the fan guard and fan ring round the cool ing fan 3 Remove the belt guard 4 Insert a 1 2 square wrench in the belt tensioner 1 Lift the wrench up and lift the water pump drive belt off 5 Insert a 1 2 square wrench in...

Page 41: ...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 do a function check 1 P0015862 Maintenanc...

Page 42: ...the first start The oil level can be read both when the engine is stopped the STOP side of the dipstick and when it is running the OPERATING side of the dipstick Never fill past the MAX limit on the oil dipstick Only use Volvo Penta recommended oils refer to Tech nical Data page 65 Only fill when the engine is stopped Fill oil through the oil filler refer to Maintenance page 42 Check that the corr...

Page 43: ...ange WARNING Hot oil and hot surfaces can cause burns 1 Clean the oil filter bracket 2 2 Remove all oil filters with a suitable oil filter extrac tor 1 3 Clean the mating surface of the oil filter bracket Make sure that no pieces of old oil seal are left behind Carefully clean round the inside of the pro tective rim 2 on the oil filter bracket 4 Put a thin layer of engine oil on the seal rings of ...

Page 44: ... 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 can not cause fire IMPORTANT Do not fill the new fuel filter with fuel before assembly There is a risk that contamination could get into the system and cause malfunctions or damage 1 Clean round the fuel filter 2 Remove the filter with a suitable filt...

Page 45: ...ower 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 fur ther half turn no more 7 Connect the cable to the water trap sensor 8 If necessary vent the fuel...

Page 46: ...c feed pump switch until water free fuel begins to run out refer to Component locations 3 Switch off the electric drain nipple 2 at the base of the primary fuel filter to close it Bleeding the Fuel System 1 Check whether there is enough fuel in the tank and that any fuel taps are open 2 Turn the ignition on 3 The fuel system is vented by depressing the electric feed pump switch for 1 to 2 minutes ...

Page 47: ... offer excellent protection against corrosion cavitation damage and bursts due to freezing Only coolants of this quality are adapted to and approved by Volvo Penta IMPORTANT Volvo Penta engines are delivered with either Volvo Penta Coolant green or Volvo Penta Coolant VCS yellow both are available as concentrates and Ready Mixed We recommend that the coolant supplied with the engine on delivery be...

Page 48: ...own to 28 C 18 F Volvo Penta Coolant green 24 C 11 F Volvo Penta Coolant VCS yellow At 60 glycol concentration the freezing point is low ered to 54 C 65 F Volvo Penta Coolant green 46 C 51 F Volvo Penta Coolant VCS yellow Never mix in more than 60 of the concentrated cool ant A greater volume of concentrate entails a reduced cooling effect with the risk for overheating and reduced anti freeze prot...

Page 49: ... empty system NOTICE Mix the correct amount of coolant in advance to ensure that the cooling system is completely filled Refer to Technical Data page 67 for the correct cool ant quantity NOTICE Do not start the engine until the system is vented and completely filled 1 Check that all drain points are closed 2 Open the filler cap 1 Do not open the pressure cap 2 3 Fill with coolant so that the level...

Page 50: ...r 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 they must 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 coolant lines 5 Shut any taps and check that the spring load...

Page 51: ...alleries The cooling system should be cleaned out when the coolant is changed IMPORTANT Cleaning must not be done if there is any risk of the cooling system freezing since the cleaning solution does not have any frost prevention ability IMPORTANT It is extremely important that the correct concentration and volume of coolant is put in the system Mix in a separate clean vessel before filling the coo...

Page 52: ...ut is completely clean Make sure that any heater con trols are set to full heating during emptying 7 If contamination should still be left after a long period of flushing you can do a cleanout with Volvo Penta radiator cleaner followed by finishing off with Volvo Penta neutralizer Carefully follow the instructions on the package Otherwise continue as in item 8 below 8 When the cooling system is co...

Page 53: ...cted when the engine is running the alternator and electronics can be dam aged 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 breaker is located on the left hand side of the engine Location of Sensors page 43 The engine stops if the fuse trips If t...

Page 54: ...cting 1 Connect the cable red to the pole on the bat tery 2 Connect the cable black to the pole on the battery Disconnecting 1 Remove the cable black 2 Remove the cable red Cleaning Keep the batteries clean and dry Contamination and oxide on the batteries and battery poles can cause stray currents voltage drop and discharge especially in wet weather Remove oxidation from the battery poles and term...

Page 55: ... carefully To avoid the risk of electrochemical corrosion when an external charger is connected the battery cables should be removed from the batteries before the charger is connected Always switch off the charging current before the charging clips are removed Charge batteries if they have become discharged During charging unscrew the cell plugs but leave them in the plug holes Ventilate well espe...

Page 56: ...s stoppage Change the oil and oil filter on the engine then warm it up afterwards More than 8 month s stoppage Conserve the lubrication and fuel systems with con servation oil Please refer section Conservation of the lubrication and fuel systems for more than 8 months stoppage Check that the coolant offers sufficient frost protec tion Top up as necessary Alternatively you can drain the coolant als...

Page 57: ...and warm it up at fast idle with no loading Check that no oil fuel or coolant leakage occurs 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 and 2 3 diesel fuel Vent the fuel...

Page 58: ...8 1065 2348 Firing order 1 5 3 6 2 4 1 5 3 6 2 4 Type designation TAD940VE TAD941VE TAD942VE TAD943 Power prime stand by Refer to the sales literature Torque Prime Standby Refer to the sales literature Compression ratio 20 2 1 20 2 1 20 2 1 20 2 1 Low idle r min 600 600 600 600 High idle rpm 2250 2250 2250 2250 No of valves 24 24 24 24 No of cylinders 6 6 6 6 Bore mm inch 120 4 72 120 4 72 120 4 7...

Page 59: ... 600 600 High idle rpm 2250 2250 2250 No of valves 24 24 24 No of cylinders 6 6 6 Bore mm inch 120 4 72 120 4 72 120 4 72 Stroke mm inch 138 5 43 138 5 43 138 5 43 Displacement inch3 9 36 571 9 36 571 9 36 571 Weight dry kg lbs 1015 2238 1015 2238 1015 2238 Weight wet kg lbs 1065 2348 1065 2348 1065 2348 Firing order 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 Technical Data 64 47702660 03 2013 AB VOLVO P...

Page 60: ...l 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 The oil must also comply with at least one of the following specifications ACEA E7 ACEA E5 Global DHD 1 API CI 4 or API CH 4 VDS Volvo Drain Specification ACEA Association des Constructeurs Européenne d Automobiles API American...

Page 61: ...olvo Penta accepts the same FAME content as in major on road fuels EN 590 and ASTM D975 i e today up to 7 without any specific additional service requirements Please contact your Volvo Penta Dealer for futher information For engines produced after 1 Jan 2009 Volvo Penta accepts with specific service requirements max 30 FAME blend FAME component in accordance with EN 14214 and diesel fuel in accord...

Page 62: ...el low colour are based on Organic Acid Technology OAT Volvo Penta Coolant and Coolant Ready Mixed green colour are silicate based 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 ASTM D859 20 mg SiO2 l Iron acc ASTM D1068 0 10 ppm Manganese acc ASTM D858 0 05 ppm Conductivity acc ASTM D1125 500 µS cm Organic con...

Page 63: ...8V 100A output app 2800 W and voltage max current 28V 140A output app 4000 W Battery capacity 2 pcs series connected 12V max 180 Ah Battery electrolyte specific gravity at 25 C fully charged battery 1 28 g cm3 1 24 g cm3 re charge battery at 1 20 g cm3 1 20 g cm3 Note Applies to batteries with tropical acid Technical Data 68 47702660 03 2013 AB VOLVO PENTA ...

Page 64: ... designation B Engine power net without fan C Max engine speed D Main software E Dataset 1 F Dataset 2 G Product number 3 1 Engine designation 2 Serial number 3 Specification number A B C D E F G P0002052 P0015924 Technical Data 47702660 03 2013 AB VOLVO PENTA 69 ...

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