Volvo Penta TAD1640GE Operator'S Manual Download

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OPERATOR’S MANUAL

Generating set and industrial engines

16 liter (EMS 2)

Summary of Contents for TAD1640GE

Page 1: ...OPERATOR S MANUAL Generating set and industrial engines 16 liter EMS 2 ...

Page 2: ...ljare om du inte har till gång till internet Dit instructieboek kan gratis via internet in een a dere taal worden besteld tot 12 maanden na aflevering http vppneuapps volvo com manual coupon Als toegang tot het internet niet mogelijk is neem dan contact op met uw Volvo Penta dealer Denne instruktionsbog kan bestilles gratis på et an det sprog via Internettet i op til 12 måneder efter leveringen ht...

Page 3: ...n 3 Introduction 7 Presentation 9 Instruments and Controls 11 Starting 22 Operation 26 Engine Shutdown 27 Fault Handling 30 Fault Code Register 36 Maintenance Schedule 49 Maintenance 51 Storage 78 Technical Data 80 Alphabetical index 89 1 ...

Page 4: ...rator s manual thoroughly and consider the advice we give on running and maintenance Please pay attention to the safety instructions contained in the manual As owner of a Volvo Penta engine we would also like to welcome you to a worldwide network of dealers and service workshops to assist you with technical advice service requirements and replacement parts Please con tact your nearest authorized V...

Page 5: ...ll your attention to the fact that this is safety information Always read such information very carefully Safety texts in the Operators Manual have the following order of priority DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury CAUTION Ind...

Page 6: ...ant can still be hot and cause scald ing Fuel filling There is always a risk of fire and explosion during fuel filling Smoking is forbidden and the engine should be stopped Never overfill the tank Shut the tank cap securely Only use the fuel recommended in the instruction book The wrong grade of fuel can cause serious mal functions power loss or stop the engine Fuel and lubrication oils Always pro...

Page 7: ...at they have the correct capacity for the lift engine weight together with auxiliaries if fitted The engine should be lifted with an adjustable lifting boom for safe handling All chains or cables should be parallel to each other and should be as square as possible to the top of the engine Please note that auxiliary equipment installed on the engine could change its center of gravity Special liftin...

Page 8: ...sh at once with soap and a lot of water If you get battery acid in your eyes flush at once with a lot of cold water and get medical assistance at once Electric welding Remove the positive and negative cables from the batteries Then disconnect all cables connected to the alterna tor Disconnect both connectors from the engine con trol module Always connect the welder earth clamp to the com ponent to...

Page 9: ...imum reli ability and long life They are not only built to withstand a demanding environment but also to have the small est possible environmental impact These qualities will be maintained through regular servicing and the use of genuine Volvo Penta replacement parts or replacement parts approved by Volvo Penta Volvo Penta has a world wide network of authorized dealers They are Volvo Penta product...

Page 10: ...u own an emission certified engine used in an area where exhaust emissions are regulated by law it is important to be aware of the following Certification means that an engine type has been checked and approved by the relevant authority The engine manufacturer guarantees that all engines of the same type conforms to the certified engine This places special demands on the care and main tenance you ...

Page 11: ...AD1650VE TAD1650GE and TAD1651GE have internal EGR Exhaust Gas Recirculation TWD1643GE TAD1650VE These are in line directly injected 6 cylinder industrial diesel engines All engines are equipped with elec tronically controlled fuel management EMS turbo charger charge air cooler thermostatically controlled cooling systems and electronic speed control 7748681 12 2011 9 ...

Page 12: ...calculate the correct fuel injection volume and timing check engine status etc Diagnostic function The task of the diagnostic function is to discover and localize any malfunctions in the EMS system to pro tect the engine and to ensure operation in the event of serious malfunction If a malfunction is discovered this is announced by warning lamps a flashing diagnostic lamp or in plain language on th...

Page 13: ...n 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 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...

Page 14: ...ng Must be 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 button...

Page 15: ...2 Press 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 sho...

Page 16: ...o stop the 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...

Page 17: ...ngine shut 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 sp...

Page 18: ...ing brightness 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 DC...

Page 19: ...al function The display will work but may act in an unex pected way The DU is connected to the engine interface connector 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 20: ... button 2 is pressed repeatedly By pressing button 5 the right arrow you choose what information to be shown in the different 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 opera...

Page 21: ...s broken there will be a straight line in the display Configuration menu Press button 5 for three seconds to enter the Config uration menu Navigate with the up 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 Instruments and Controls 7748681 12 2011 19 ...

Page 22: ...0MINS 30MINS 60MINS 2HRS 4HRS 8HRS SYSTEM 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...

Page 23: ...ps connectors 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 ...

Page 24: ... to Oil level checking and topping up Open the fuel valves Check the fuel pre filter refer to Draining conden sate fuel system page 65 Check that no leakage of oil fuel or coolant is pres ent Check the coolant level and that the radiator is not blocked externally Refer to Coolant Level Check ing and Topping Up page 68 and Charge Air Cooler External Cleaning page 70 WARNING Do not open the coolant ...

Page 25: ...eating DCU 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 ...

Page 26: ...r to the Main tenance lubrication system 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 t...

Page 27: ...the red jumper 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 terminalon the starter motor 3 Start the engine WARNING Do not touch the connections during the start attempt Risk of arcing Do not bend over an...

Page 28: ...Avoid long term operation at idle or at low load since this can lead to increased oil consumption and even tually to oil leakage from the exhaust manifold since oil will seep past the turbocharger seals and accom pany the induction air into the inlet manifold at low turbo pressure One consequence of this is carbon build up on valves piston crowns exhaust ports and the exhaust turbine At low loads ...

Page 29: ...the clutch 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 I...

Page 30: ...on of the extra stop please refer to Location of Sensors page 55 WARNING Working with or going close to a running engine is a safety risk Watch out for rotating components and hot surfaces Engine Shutdown 28 7748681 12 2011 ...

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Page 32: ...Function Engine 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...

Page 33: ... air filter 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...

Page 34: ...gister together with information about cause reaction and actions for further information see chapter Fault Code Register CIU Control Interface Unit When the system detects a malfunction the diagnos tics lamp flashes If the diagnostics button is pressed and then released a fault code is flashed out The fault code consists of two groups of flashes sep arated by a pause of two seconds A fault code i...

Page 35: ... 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 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 actio...

Page 36: ... To get to the fault list when no fault codes are set press the SEL button and select Diagnos tics from the menu Easy Link Instruments 1 When the system detects a fault the diagnostics lamp flashes 2 Press the diagnostics button The fault code is shown as text in the tachometer display 3 Look up the fault code in the Fault Code Register and take the necessary actions 4 When the fault has been rect...

Page 37: ...w 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 fault code can then be erased with the VODIA tool 2 must be acknowledge and read out every time the engine is switched on If the diagnostic button is depressed after the fault has been corrected and fault code deleted the code 1 1 No fault will ...

Page 38: ...ensor cable is not damaged Check that the fuel pressure sensor is correctly installed Check fuel pressure sensor function Fuel Pressure Code 3 8 PID SPN 94 Cause Reaction Remedy Low supply pressure None Check if it is possible to build up pressure with the hand pump Check the fuel filter Check the fuel pre filter Water in Fuel Code 2 1 PID SPN 97 Cause Reaction Remedy Water in fuel None Empty the ...

Page 39: ...lter is not blocked Check system pressure valves and safety valves in the oil system Check oil pressure sensor function Boost Temperature Sensor Code 3 2 PID SPN 105 Cause Reaction Remedy Short circuit to positive or earth ground Open circuit None Check that the boost temper ature sensor connector is cor rectly installed Check that the boost temper ature sensor cable is not dam aged Check that the...

Page 40: ...r engine stops Check that the charge air pressure sensor connector is correctly installed Check that the charge air pressure sensor cable is not damaged Check that the charge air pressure sensor is correctly installed Check charge air temperature sensor function Air Filter Pressure Code 5 5 PID SPN 107 Cause Reaction Remedy Too large pressure drop across filter Less good response from engine Check...

Page 41: ...ystem Check the pressure cap on the expansion tank Check coolant temperature sensor function Check thermostat function Coolant Level Code 2 2 PID SPN 111 Cause Reaction Remedy Low coolant level Engine control module reduces engine power unless the protection has been shut off with the VODIA diagnostic tool Check the coolant level Check coolant level monitor function Coolant Level Sensor Code 2 3 P...

Page 42: ...one Check the supply voltage from the control unit Battery Voltage CIU Code 6 9 PID SPN 158 Cause Reaction Remedy Short circuit to negative Faulty alternator Faulty battery battery cables Problems in engine starting Check the supply voltage from the control unit Check the batteries Check the alternator Check the 8 pin contact Air Temperature Sensor Inlet Code 7 9 PID SPN 172 Cause Reaction Remedy ...

Page 43: ... tem perature sensor connector is properly mounted Check that the wiring to the exhaust temperature sensor is not damaged Check that the exhaust tem perature sensor is correctly mounted Check the exhaust tempera ture sensor function Oil Temperature Sensor Code 3 7 PID SPN 175 Cause Reaction Remedy Shorted to plus or minus Break None Check that the cable harness to the oil temperature sensor has no...

Page 44: ...ng this time When a fault code is active the engine can be started but not stopped Check that the starter switch connections are not damaged Check that the ignition switch cable is not damaged Stop Input EMS Code 4 8 PPID 6 SPN 970 Cause Reaction Remedy Short circuit to negative Open circuit Engine can only be stopped with the auxiliarystop Check that the starter switch connections are not damaged...

Page 45: ... Reaction Remedy Control unit too hot incorrect assembly Electrical fault damaged sen sor None Check the control unit instal lation Recommended ambi ent temperature is 50 C 122 F Speed Potentiometer Connected to CIU Code 2 8 PPID 132 SPN 91 608 Cause Reaction Remedy Shorted to plus or minus Fault in sensor Engine goes to idle Speed feezes Check that the potentiometer has been connected correctly C...

Page 46: ...ply pressure Check the valve clearance Do a compression test and check cylinder 3 Injector Cylinder 4 Code 7 4 SID 4 SPN 654 Cause Reaction Remedy Electrical fault Faulty compression or injec tor Engine runs on 5 cylinders Abnormal sound Reduced performance Check that the injector cables are not damaged Check that the injector con nections are not damaged Check fuel supply pressure Check the valve...

Page 47: ...talled in the upper timing gear cover Check engine speed sensor function Flywheel Speed Sensor Code 2 4 SID 22 SPN 637 Cause Reaction Remedy No signal Abnormal frequency Intermittent signal from the sensor Fault in sensor Engine is very difficult to start and runs roughly when it starts Check that the sensor con nector is correctly installed Check that the engine speed sensor cable is not damaged ...

Page 48: ...gine management unit are not damaged Check that sleeves 11 and 12 in the connector on the CIU are not damaged TWD1643GE Power Supply to Sensor Code 9 3 SID 211 232 SPN 1079 1080 Cause Reaction Remedy Shortcut Fault in sensor Faulty values in oil pressure and boost pressure sensors Fault code for oil pressure and boost pressure sensor Low engine output The instrument shows zero oil pressure and boo...

Page 49: ...tween the CIU DCU and the engine management unit are not damaged Data Set Memory EEPROM CIU Code 9 8 SID 253 SPN 630 Cause Reaction Remedy Internal fault in control mod ule Programming faulty Engine does not start Re program the control mod ule Data Set Memory EEPROM EMS Code 9 9 SID 253 SPN 630 Cause Reaction Remedy Internal fault in control mod ule Internal fault in control mod ule Engine does n...

Page 50: ... the fan actuator is correctly mounted Check the fan actuator EATS Fault codes for the EATS system is in the installation manual for this system Calibration memory EEPROM SID 232 SPN 628 Possible reason Reaction Action Control unit None Check cables and connec tions CAN1 J1939 time out PSID 201 SPN 2029 Possible reason Reaction Action Faulty harness Faulty sensor Faulty fuse None Fault only visibl...

Page 51: ...aintenance job at the interval which is reached first Service 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 condensed water I Coolant Level I Drive Belts I Star...

Page 52: ...ilter 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 1 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 1 TWD1643GE E Every 4000 hours At least every month 12 24 48 Belt Te...

Page 53: ... on how to carry out maintenance and service operations in a safe and correct manner 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 Read about security measures fo...

Page 54: ... TAD1650GE TAD1651GE 1 AC generator 2 Control unit EMS 2 3 Air Filter 4 Oil dipstick 5 Fuel filter with fuel pressure monitor 6 Fuel prefilter with water monitor 7 Expansion tank 8 Charge air cooler TAD 9 Starter motor 10 Oil Filter Maintenance 52 7748681 12 2011 ...

Page 55: ... 4 Oil dipstick 5 Fuel filter with fuel pressure monitor 6 Fuel pre filter with water monitor 7 Air filter 8 HP turbo 9 LP turbo 10 Expansion tank 11 Starter motor located behind charge air cooler 12 Charge air cooler LP turbo 13 Oil filter Maintenance 7748681 12 2011 53 ...

Page 56: ...1650VE 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 54 7748681 12 2011 ...

Page 57: ...n fuel sensor 2 Charge air pressure and temperature sensor 9 Oil level and temperature sensor 3 Air filter indicator 10 Fuel pressure sensor 4 Flywheel position and engine speed sensor 11 Crankhouse pressure sensor 5 Fuse 12 Coolant temperature sensor 6 Aux stop 13 Piston cooling pressure sensor not TAD1650 51GE 7 Oil pressure sensor 14 Camshaft position sensor Maintenance 7748681 12 2011 55 ...

Page 58: ...ankhouse pressure sensor 3 Oil pressure sensor 11 Coolant temperature sensor 4 Airfilter indicator 12 Exhaust temperature sensor 5 Aux stop 13 Piston cooling pressure sensor 6 Fuse 14 Flywheel position and engine speed sensor 7 Water in fuel sensor 15 Camshaft position sensor 8 Fuel pressure sensor 16 Solenoid valve drainage water trap optional not shown in illustration Maintenance 56 7748681 12 2...

Page 59: ...emperature sensor 2 Charge air pressure and temperature sensor 8 Water in fuel sensor 3 Flywheel position and engine speed sensor 9 Fuel pressure sensor 4 Fuse 10 Coolant temperature sensor 5 Aux stop 11 Piston cooling pressure sensor 6 Oil pressure sensor 12 Camshaft position sensor Maintenance 7748681 12 2011 57 ...

Page 60: ...tected 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 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...

Page 61: ...the condition of the charge air hoses hose unions and clamp condition for cracks and other dam age Change as necessary IMPORTANT Clamps must be tightened using a torque wrench to 9 2 Nm 6 6 1 5 lbf ft P0002083 Maintenance 7748681 12 2011 59 ...

Page 62: ...stem 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 the belt tensioner 2 Press the wrench down and remove the alternator belts 6 Check that the pulleys are clean and undamaged 7 Press the 1 2 wrench in the belt te...

Page 63: ... 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 P0002086 TAD1640GE TAD1641GE TAD1642GE TAD1650GE TAD1651GE TA...

Page 64: ... the dipstick and with the engine running the OPERATING side of the dipstick Do not fill up above the maximum oil level Only use a recommended grade of oil please refer to Tech nical Data page 82 The oil level sensor only measures the oil level at the time when the ignition is turned on In other words not continually during operation TAD1650VE The oil level must be inside the marked area on the di...

Page 65: ...lter Change 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 ri...

Page 66: ...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 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 suita...

Page 67: ...he 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 system please refer to Bleeding the Fuel System page 65 Draining condensate fuel system NOTICE Put a collection vessel under the fuel filter tocollect the condensate and fuel 1 Open the drain nipple 1 in ...

Page 68: ... Volvo Penta Coolant VCS yellow both are available as concentrates and Ready Mixed Volvo Penta coolants have been prepared to work best with Volvo Penta engines and 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 We recommend that the coolant supplied with the engine on delivery be us...

Page 69: ...lammable IMPORTANT Different kinds of coolant must not be mixed with each other Mix 40 concentrated coolant and 60 water This mixture protects against internal corrosion cavi tation and bursts due to freezing down to 28 C 18 F A 60 glycol admix lowers the freezing point to 54 C 65 F Never mix more than 60 concentrate in the coolant A greater concentration provides reduced cooling effect with the r...

Page 70: ...ant recommended by Volvo Penta NOTICE Open only the filler cap 1 Do not open the pressure cap 2 NOTICE TWD1643GE The cap 2 is both filler cap and pressure cap Check the coolant level daily before starting 1 Check that the coolant level is above the MIN mark on the expansion tank 2 Top up with coolant as required so that the level is between the MIN and MAX marks TWD1643GE Fill the expansion tank t...

Page 71: ...llow trapped air to escape If a heating unit is connected to the engine cooling system the heat control valve should be opened and the installation vented during filling 5 Stop the engine after about an hour and check the coolant level Top up as necessary TWD1643GE 1 Open the caps to both the expansion tank 1 and radiator 2 2 Fill coolant into the expansion tank until it is com pletely full 3 Fill...

Page 72: ...se The drain 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 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 Shut any ta...

Page 73: ...ooling galleries 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...

Page 74: ...t runs out 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 syst...

Page 75: ... 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 sponge A...

Page 76: ...unning 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 55 The engine stops if the fuse trips If the circuit breaker trips ...

Page 77: ...battery acid comes in contact with the eyes flush immediately with plenty of water and obtain medical assistance without delay Connecting and disconnecting the battery Connecting 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 Contaminatio...

Page 78: ... batteries Always use protective goggles and gloves If battery electrolyte comes into contact with unprotected skin whas off immediately using plenty of water and soap If battery acid comes in contact with the eyes flush immediately with plenty of water and obtain medical assistance without delay WARNING Never confuse the positive and negative poles on the batteries Risk of arcing and explosion IM...

Page 79: ...used for a longer period of time the batteries should be fully charged then possibly trickle charged please refer to the battery manu facturer s recommendations Batteries are dam aged by being left discharged and can also freeze and burst easier in cold weather Special instructions apply to boost charging Boost charging can shorten battery life and should there fore be avoided P0002111 Maintenance...

Page 80: ...8 month 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 coo...

Page 81: ... engine 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 ...

Page 82: ... 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 High idle rpm 1500 1800 1500 1800 1500 1800 1500 1800 Type designation TAD1650GE TAD1651GE Power prime stand by Refer to the sales literature Torque Prime Standby Refer to the sales literature No of cylinders 6 6 Bore mm inch 144 5 67 144 5 67 Stroke mm in...

Page 83: ... 67 144 5 67 144 5 67 Stroke mm inch 165 6 50 165 6 50 165 6 50 Displacement liter inch3 16 12 983 9 16 12 983 9 16 12 983 9 Weight dry kg lb 1480 3263 1480 3263 1425 3142 Weight wet kg lb 1550 3417 1550 3417 1495 3296 Firing order 1 5 3 6 2 4 1 5 3 6 2 4 1 5 3 6 2 4 Compression ratio 17 5 1 17 5 1 18 0 1 Low idle r min 600 600 700 High idle rpm 1800 1800 1800 2000 Technical Data 7748681 12 2011 8...

Page 84: ...ICE Mineral based oil as well as fully or semi synthetic can be used on condition that it complies with thequality requirements above 1 If sulfur content is 1 0 by weight use oil with TBN 15 2 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 Auto...

Page 85: ... fuels Volvo 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 i...

Page 86: ...C 186 8 F TAD1650VE TWD1643GE 82 C 179 6 F Coolant Volvo Penta Coolant VCS and VCS Ready Mixed yel 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 D...

Page 87: ...uipment optional voltage max current 28V 110A power app 2800W Battery capacity 2 pcs series connected 12 V max 220 Ah Battery electrolyte density at 25 C fully charged battery 1 28 g cm3 1 24 g cm3 recharge battery at 1 20 g cm3 1 20 g cm3 Note Applies to batteries with tropical acid Technical Data 7748681 12 2011 85 ...

Page 88: ...r 2 A Engine 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 Technical Data 86 7748681 12 2011 ...

Page 89: ...ion ignition engines The partially completed machinery also complies with the following relevant Directive 2004 108 EC Electromagnetic Compatibility EMC Directive Applied Standards EN 61000 6 1 EN 61000 6 2 EN 61000 6 3 EN 61000 6 4 EN 12895 EN ISO 14982 and EN 13309 Declaration for the installation of partially completed machinery in accordance with Machinery Directive 2006 42 EC Engine Manufactu...

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Page 91: ... and Alternator Belt Inspection 60 Drive Belt Change 61 DU Display Unit 17 E Easy Link Instruments 21 Electrical Connections 74 EMS Engine Management System 10 Engine Fuel Filter Replacement 64 Engine Oil Change 63 Engine General 58 Engines 9 Erasing fault codes 35 Extra Stop 28 F Fault Tracing 30 Fuel Pre filter Change 65 Fuel System 64 I Identification Numbers 86 L Location of Sensors 55 Lubrica...

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Page 93: ... 2011 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper ...

Page 94: ...7748681 English 12 2011 ...

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