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20

Maintenance

This chapter describes how the specified maintenance points should be done. Read them carefully before start-
ing work. The times when maintenance points need to be attended to are given in the previous chapter: Mainte-
nance schedule

WARNING!

Read through the safety advice for care and maintenance work in the “Safety information”

chapter before starting work.

WARNING!

Care and maintenance work should be done with the engine stopped unless otherwise speci-

fied. Make it impossible to start the engine by removing the ignition key and cutting the system voltage with
the main switch. Working with, or going close to a running engine is a safety risk. Watch out for rotating
components and hot surfaces.

Engine, general

Air filter Check/change.

Change the air filters when the indicator remains in
the red field after the engine has been stopped. Re-
instate the pressure drop indicator after changing the
filter, by pressing in the button.

NOTE!

The filters should not be touched until the

indicator shows the red field. Scrap the old filters. No
cleaning or re-use may be done.

IMPORTANT!

In continuous operation, the fil-

ters should be checked every 8 hours.

When operated in extremely dirty conditions,
such as coal mines, stone crushing mills etc.,
special filters are needed (not sold by Volvo
Penta).

Air hoses. Leakage check.

Inspect the condition of the hoses, for cracks and
other damage. Change as necessary. Test all hose
clamps for tightness.

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Содержание TAD420VE

Страница 1: ...Generating set and industrial engines 4 7 liter EDC 4 OPERATOR S MANUALp ...

Страница 2: ...y applications under some of the most rigorous conditions imaginable This is not by chance After more than 90 years of producing engines the name Volvo Penta has come to symbolize reliability technical ingenuity first class per formance and longevity We believe that these characteristics are also ultimately your requirements and expectations for new Volvo Penta industrial engines To make certain t...

Страница 3: ...16 Fault indication 16 Engine speed control 16 Operation at low load 16 Stopping the engine 17 Before stopping 17 Stop 17 After stopping 17 Maintenance schedule 18 Maintenance schedule 18 Maintenance 20 Engine general 20 Lubrication system 22 Cooling system 24 Fuel system 29 Electrical system 31 Laying up 35 Conservation 35 Removing conservation preparations 35 Fault tracing 36 Symptoms and possib...

Страница 4: ...s malfunctions if the instruction is ignored IMPORTANT Is used to call attention to things which could cause damage or malfunctions to product or property NOTE Is used to call attention to important information to facilitate work processes or opera tion This symbol is used on our products in some cases and refers to important information in the instruction book Make sure that warning and informati...

Страница 5: ...injury When engines are supplied without touch guards all rotating components and hot surfaces must be pro tected after installation in their application if neces sary for personal safety Ignition lock If the instrument panel does not have a key switch the engine room must be lockable to prevent unau thorized persons from starting the engine Alterna tively a lockable main switch can be used Care a...

Страница 6: ...al spare parts Components in fuel systems and electrical systems on Volvo Penta engines are designed and manufac tured to minimize the risk of explosions and fire in accordance with applicable legal requirements The use of non original spare parts can cause an ex plosion or fire Batteries Batteries contain and give off an explosive gas espe cially when charged This gas is very flammable and highly...

Страница 7: ...stem the engine must be stopped and the current cut by switching off the main switch es External current supply for engine heaters battery chargers or other auxiliary equipment connected to the engine must be disconnected Batteries Batteries contain a highly corrosive electrolyte Pro tect your eyes skin and clothes during charging and other handling of batteries Always use protective goggles and g...

Страница 8: ...llows Use the engine in normal operation Full load should only be applied for short periods Never run the en gine for a long period of time at constant speed dur ing this period Higher oil consumption is normal during the first 100 200 hours of operation For this reason check the oil level more frequently than normally recommended When an opening clutch is installed this should be checked more car...

Страница 9: ... No seals may be broken by unauthorized person nel The general advice in the instruction book about ope ration care and maintenance applies IMPORTANT Delayed or inferior care main tenance and the use of non original spares mean that AB Volvo Penta can no longer be responsible for guaranteeing that the engine complies with the certified version Damage injury and or costs which arise from this will ...

Страница 10: ...520GE TAD520GE TAD520VE TD720GE TAD720GE TAD720VE TAD721GE TAD721VE TAD722GE TAD722VE Replaceable dry cylinder liners TAD620VE Liner less TD420VE TAD420VE Cast aluminum pistons with oil cooling Three piston rings with a keystone type top ring Induction hardened overhead camshaft with valve lifters and push rods Two valves per cylinder Replaceable valve seats and valve guides does not apply to TD42...

Страница 11: ...Presentation 9 TD420VE TAD420VE TAD620VE TD520GE TAD520GE TAD520VE TD720GE TAD720GE TAD720VE TAD721GE TAD721VE TAD722GETAD722VE ...

Страница 12: ...er s identification code 8 Indication of standard and or specification 9 Air temperature in C F in accordance with ISO 3046 10 Altitude above mean sea level in accordance with ISO 3046 11 EP code for injection pump cylinder 1 on top 12 Piston class 13 Extra information Location of engine signs The engines are supplied with two engine signs of which one is installed on the right side of the engine ...

Страница 13: ...he CAN interface or with Volvo s VODIA tool including the Penta EDC4 soft ware at an authorized Volvo Penta workshop Summary The system includes sensors control unit and an en gine speed regulator The sensors send input signals to the control unit which controls the control rod for the injection pumps in its turn by means of an actua tor in the engine speed regulator Input signals The control unit...

Страница 14: ...omer The functions available are described below A Engine speed potentiometer throttle control B CAN interface SAE J 1939 C VODIA input D Droop contact E 1500 1800 rpm switch F Diagnostic button G Tachometer H Warning lamp oil pressure J Diagnostic lamp K Warning lamp high coolant temperature L Fuse 15 A M Main switch N Battery 24 12 V ...

Страница 15: ...t level and that the radiator is not blocked externally Please refer to the Main tenance cooling system chapter WARNING Do not open the expansion tank cap when the engine is hot Steam or hot fluid could spray out Turn the main current on IMPORTANT Never disconnect the current with the main switch es when the engine is running This will damage the alternator Move the engine speed control to idle an...

Страница 16: ...ecommended viscosity for the relevant tem perature should be used Please refer 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 elec tric engine heater In extreme cases a diesel burning engine heater may be needed Ask your Volvo Penta dealer for advice IMP...

Страница 17: ...nnected series or parallel so that the rated voltage cor responds 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 auxil iary battery and lastly to a place some distance from the flat batteries such as the negative cable by the main switch or the negative cable connection on the starter mo...

Страница 18: ...e engine e g high coolant temperature Reaction The engine goes into limp home mode The diagnostic lamp lights up 3 The diagnostic function has discovered a serious malfunction which makes it impossible to control the engine Reaction The diagnostic lamp starts to flash Engine is shut off Engine speed control Avoid sudden and violent throttle opening Operation at low load Avoid long term operation a...

Страница 19: ...s without load before stopping it This permits the temperature in side the engine to even up after boiling is avoided at the same time as the turbocharger cools some what This contributes to long service life without malfunctions Stop Disengage the clutch if possible Depending on the equipment installed press the stop button and keep it depressed until the engine has stopped or turn the key to the...

Страница 20: ...hould be changed when the indicator remains in the red field after the engine has been stopped 3 When operated in extremely dirty conditions special air filters must be used After the first 100 200 hours Valve clearance check not shown Injectors re tighten 50Nm 36 88 lbf ft not shown Every 50 hours Battery checking the electrolyte level page 32 Release bearing lubrication 1 not shown 1 Applies to ...

Страница 21: ...with an anti corrosion mixture Every 1000 hours Air hoses leakage check page 20 Fuel filter changing page 29 Every 1500 hours Valve clearance inspection adjustment not shown Every 2000 hours or every 12 months Air filter for air compressor change not shown Air filter clean TAD engines 1 not shown Coolant corrosion protection fluid change page 24 25 1 When operated in extremely dirty conditions it ...

Страница 22: ...se to a running engine is a safety risk Watch out for rotating components and hot surfaces Engine general Air filter Check change Change the air filters when the indicator remains in the red field after the engine has been stopped Re instate the pressure drop indicator after changing the filter by pressing in the button NOTE The filters should not be touched until the indicator shows the red field...

Страница 23: ...o press the belts down about 10 mm 3 16 between the pulleys Worn belts which operate in pairs should be changed together On TD420VE TAD420VE and TAD620VE the fan belts have an automatic belt tensioner and do not need to be adjusted TD520GE TAD520GE TAD520VE TAD620VE TD720GE TAD720GE TAD720VE TAD721GE TAD721VE TAD722GE and TAD722VE have me chanical belt tensioners Always check the condition of the ...

Страница 24: ...vals should be changed VDS Volvo Drain Specification Global DHD Global Diesel Heavy Duty ACEA Association des Constructeurs Européenne d Automobiles API American Petroleum Institute TBN Total Base Number Lubrication system Teor de enxofre no combustível por peso Motor Grau do óleo 0 5 0 5 1 0 1 0 1 Intervalo de mudança de óleo conforme o que primeiro ocorrer T A D420 620VE VDS 3 500 h 12 meses 250...

Страница 25: ... 3 Remove the bottom plug Drain the oil 4 Install the bottom plug with a new gasket 5 Remove the filer 1 Check that the gasket has not been left behind on the engine 5 Fill the new filters with engine oil and wipe oil on the gaskets Screw the filters on by hand until the gaskets just touch the mating surface Then turn the filter a further half turn Not more 6 Fill up with oil to the correct level ...

Страница 26: ...consistency must be used all year round This applies even if there is never any risk for frost to ensure that the engine has an adequate protection against corrosion Future warranty claims on the engine and additional equipment may be rejected if an unsuitable coolant has been used or if the instructions concerning coolant mixing have not been followed NOTE The anti corrosive agents become less ef...

Страница 27: ...the risk of overheating and will give reduced freezing protec tion IMPORTANT Coolant must be mixed with pure water use distilled de ionized water The water must fulfill the requirements specified by Volvo Penta see Water quality IMPORTANT It is extremely important that the correct concentration of coolant is added to the system Mix in a separate clean vessel before adding into the cooling system E...

Страница 28: ... Filling a completely empty system Check that all drain points are closed The location of drain and vent taps is shown overleaf Filling should be done with the engine stationary Fill up slowly to allow the air to flow out If a heating unit is connected to the engine cooling system the heat control valve should be opened and the installation vented during filling Fill up with coolant to the correct...

Страница 29: ... out Open the drain taps and remove the drain plugs po sitions are shown below Unscrew and empty the coolant filter if installed IMPORTANT Deposits which must be cleared away may be found inside the drain plugs taps Check that all coolant really does drain out Drain vent taps Location Drain plugs P under the radiator beside cyl 3 or cyl 5 4 or 6 cylinder engines under the oil cooler Vent tap 1 On ...

Страница 30: ...diator and flush with fresh water until the water which runs out is completely clear 3 Close the drain taps and plugs Fill up with fresh coolant as in the instructions in the chapter en titled Coolant Checking and filling Radiator air cooled intercooler TAD External cleaning Remove guards as necessary to access the radiator Clean with water and a mild detergent Use a soft brush Be careful not to d...

Страница 31: ... on hot surfaces Remove the filters Wipe a film of oil on the gaskets of the new filters Screw the filters on by hand until the gaskets just touch the mating surface Then tighten a further half turn no more Vent the fuel system Hand old filters in to an authorized waste pro cessing facility for destruction Start the engine and make sure that no leakage oc curs Fuel specification The fuel must comp...

Страница 32: ...ng The fuel system must be vented after a filter change if the fuel tank has been run dry after a long term stoppage etc Use the hand pump if fitted to vent the fuel system In other cases vent the system by operating the starter motor ...

Страница 33: ...if the instrument stop working during operation a fuse or circuit break er can have tripped Check and replace fuses or re set circuit breakers IMPORTANT Always investigate the reason for the overload Main switch The main switch must never be disconnected before the engine has been stopped If the circuit between the alternator and the battery is disconnected when the engine is running the alternato...

Страница 34: ...nnect the cable red to the pole on the battery Then connect the cable black to the pole on the battery When you disconnect batteries connect the cable black first then the cable red Cleaning Keep the batteries dry and clean Contamination and oxide on the batteries and battery poles can cause stray currents voltage drop and discharge especially in wet weather Clean oxidation from the battery poles ...

Страница 35: ...ly trickle charged please refer to the battery manufacturer s recommendations Batteries are damaged by being left discharged and can also freeze and burst easier in cold weather IMPORTANT Observe the instruction manual for the battery charger carefully To avoid the risk of electrochemical corrosion when an external charger is connected the battery cables should be removed from the batteries before...

Страница 36: ... sensor camshaft 2 Speed regulator Actuator 3 Coolant temperature sensor 4 Charge pressure sensor 3 pin 5 Charge pressure sensor 4 pin 6 Connection to control unit 7 Fuel temperature sensor 8 Oil pressure sensor Only one type of sensor is used ...

Страница 37: ...ot offer any protection against frost If there is any risk of frost the system must be drained Drain any water and contamination from the fuel tank Fill the fuel tank completely to avoid conden sation Clean the outside of the engine Do not use a power washer Touch up paint damage with Volvo Penta original paint Disconnect the batteries Clean and charge the batteries NOTE A poorly charged battery c...

Страница 38: ...lant temperature 20 No or poor charge 2 23 1 Flat batteries 2 Poor contact open circuit in cables 3 Main switch turned off 4 Faulty ignition lock 5 Faulty main relay 6 Faulty starter motor relay 7 Faulty starter motor solenoid 8 Lack of fuel fuel taps closed fuel tank empty wrong tank connected 9 Blocked fuel filter pre filter because of contamination or paraffin fraction separation in fuel at low...

Страница 39: ... and then released a fault code is flashed out from the diagnostic lamp The fault code is found in the fault code list with information about the reason reaction and measures to be taken Please refer to the Fault codes chapter Effect on engine The diagnostic function affects the engine in the fol lowing ways 1 The diagnostic function has discovered a minor malfunction which does not damage the eng...

Страница 40: ... 3 seconds and then releasing it The diagnos tic lamp goes out and a fault code is then flashed out The fault code consists of three groups of flashes separated by a pause of two seconds The first and third group consist of short flashes 0 4 s The second group consists of long flashes 0 8 s A fault code is obtained by counting the number of flashes in each group Example 2 short pause 2 long pause ...

Страница 41: ...shut off Action Check that the engine speed sensor is installed with the correct distance to the camshaft Check the cables for the engine speed sensor for breaks and short circuits Check the connector for poor contact Check engine speed sensor function Change the sensor as necessary PID 190 Code 2 1 4 Overspeed Reason The engine speed is or has been higher than the permissible limit Reaction Fuel ...

Страница 42: ...e Reaction A fault code is generated The fault code disappears when the coolant temperature falls below the recuperation value Action Check the coolant Check the sensor cable for breaks and short cir cuits Check sensor function Change the sensor as necessary PID 102 Code 2 2 3 Charge pressure sensor Reason Faulty sensor connector or cable Reaction A fault code is generated Action Check the sensor ...

Страница 43: ...function Change the sensor as necessary Check the limit value for engine shut off due to coolant pressure PID 111 Code 2 3 5 Warning coolant level Reason Coolant level too low Reaction A fault code is generated Action Check the coolant level Check the sensor cable for breaks and short cir cuits Check sensor function if installed Change the sensor as necessary NOTE The engine is supplied without a ...

Страница 44: ...1 Code 2 7 1 Communication fault CAN bus Reason CAN controller for CAN bus is faulty Reaction Action Check the cables Check the control unit PID 111 Code 2 3 5 Emergency stop coolant level Reason Low coolant level Reaction The engine is emergency stopped and can not be re started until the fault is rectified Action Check coolant level Check the sensor cable for breaks and short cir cuits Check sen...

Страница 45: ... 8 2 Reference voltage 1 Reason Reference voltage for actuator exceeds per missible limit values Reaction A fault code is generated The fault code disappears when the voltage returns to within the permissible limit values 5 V Action Check the voltage supplied Turn the ignition off and on and check if the fault code remains PID 158 Code 2 8 2 Reference voltage 2 Reason Reference voltage for actuato...

Страница 46: ...lt code remains SID 253 Code 2 10 1 Parameter fault Reason No data or incorrect data fault only occurs during parameter setting or reset Reaction Engine can not be started Action Check parameter settings Turn the ignition off and on and check if the fault code remains SID 240 Code 2 10 1 Stack overflow Reason Internal calculation fault Reaction The engine is emergency stopped and can not be re sta...

Страница 47: ...pm 1500 1500 1500 Low idle rpm 800 800 800 Highest full load speed rpm 2000 2500 1 2000 2500 1 2000 2500 1 Weight dry lb 380 838 2 380 838 2 495 1091 2 Type designation TAD520VE Direction of rotation seen from flywheel Anti clockwise No of cylinders 4 Cylinder bore mm inch 108 4 25 Stroke mm inch 130 5 12 Cylinder volume liter inch 3 4 76 290 No of valves 8 Compression ratio EPA 1 18 1 1 COM2 EPA2...

Страница 48: ...i clockwise No of cylinders 4 4 6 6 Cylinder bore mm inch 108 4 25 108 4 25 108 4 25 108 4 25 Stroke mm inch 130 5 12 130 5 12 130 5 12 130 5 12 Cylinder volume liter inch 3 4 76 290 4 76 290 7 15 436 3 7 15 436 3 No of valves 8 8 12 12 Compression ratio EPA1 17 5 1 17 5 1 17 1 1 17 1 1 EPA2 17 5 1 17 5 1 17 1 1 17 1 1 Injection sequence 1 3 4 2 1 3 4 2 1 5 3 6 2 4 1 5 3 6 2 4 Engine power At 1500...

Страница 49: ...5 3 6 2 4 1 5 3 6 2 4 Engine power at 1500 rpm kW cv 183 249 1 201 273 1 at 1500 rpm kW cv 201 277 1 225 306 1 Torque Nm lbf ft 1165 859 1280 944 At engine speed rpm 1500 1500 Torque Nm lbf ft 1082 798 1193 880 At engine speed rpm 1800 1800 Low idle rpm 800 950 800 950 Highest full load speed rpm 1500 1800 1 1500 1800 1 Weight dry lb 785 1731 2 785 1731 2 Weight total lb 826 1821 2 826 1821 2 1 Se...

Страница 50: ...8 psi TD420VE TAD420VE TAD620VE TAD520VE TAD720VE TAD721VE TAD722VE 450 kPa 65 psi Idle 800 rpm min TD420VE TAD420VE TAD620VE TAD520VE TAD720VE TAD721GE TAD721VE TAD722GE TAD722VE 80 kPa 11 6 psi TD520GE TAD520GE TD720GE TAD720GE 150 kPa 22 psi Automatic stop at pressure less than TD420VE TAD420VE TAD620VE TAD520VE TAD720VE TAD721VE TAD722VE 50kPa 7 2 psi TD520GE TAD520GE TD720GE TAD720GE TAD721GE...

Страница 51: ...pass valve Opening pressure 360 440 kPa 52 2 63 8 psi Fuel specification The fuel must comply with national and international standards for commercially supplied fuels such as EN 590 with nationally adapted environmental and cold requirements ASTM D 975 No 1 D and 2 D JIS KK 2204 Sulfur content Complying with legal requirements in each country Low density fuel urban diesel in Sweden and city diese...

Страница 52: ... TAD721VE TAD722GE TAD722VE 9 8 liter 2 59 US gal Volume engine radiator and hoses TD520GE 17 5 liter 4 62 US gal TAD520GE 19 7 liter 5 2 US gal TD720GE 22 liter 5 8 US gal TAD720GE 23 8 liter 6 3 US gal TAD721GE TAD722GE 27 3 liter 7 2 US gal Thermostat Quantity and type 1 piston thermostat Opening temperature TD420VE TAD420VE TAD620VE TD520GE TAD520GE TD720GE TAD720GE 83 C 181 F TAD520VE TAD720V...

Страница 53: ...Notes ...

Страница 54: ...Notes ...

Страница 55: ...Notes ...

Страница 56: ...oder als Fax an Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Schweden Fax 46 31 545 772 Die Bestellung kann auch über das Internet erfolgen http www volvopenta com manual coupon Ja ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten Publikationsnummer 7745203 Name Anschrift Land 42200 615001 155099900192 Noter que l offre est valable 12 mois ...

Страница 57: ...a la misma es válida siem pre que haya existencias Franquear o enviar fax a Document Distribution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Suecia Fax 46 31 545 772 El pedido puede hacerse tam bién por internet http www volvopenta com manual coupon Sí gracias deseo recibir gratuitamente un libro de instrucciones en español Número de publicación 7745205 Nombre Dirección País 42200 ...

Страница 58: ...ution Center Order Department ARU2 Dept 64620 SE 405 08 Göteborg Ruotsi Fax 46 31 545 772 Tilauksen voi tehdä myös Internetissä http www volvopenta com manual coupon Kyllä kiitos haluan suomenkielisen ohjekirjan veloituksetta Julkaisunumero 7745207 Nimi Osoite Maa 42200 615001 155099900192 Notar que a oferta é válida por um período de 12 meses a partir da data de ent rega do motor Depois desse per...

Страница 59: ...áíôßôõðï ôïõ åã åéñéäßïõ ñÞóçò óôçí áããëéêÞ ãëþóóá ùñßò êáìéÜ ñÝùóç Áñéèìüò Ýêäïóçò 7745210 íïìá Äéåýèõíóç þñá 42200 615001 155099900192 К Вашему сведению это предложение действительно в течение 12 месяцев от даты поставки двигателя в дальнейшем оно зависит от наличия Отправьте этот талон почтой или факсом на имя Центр подготовки документации и распространения Отдел обработки заказов ARU2 Отд 6462...

Страница 60: ......

Страница 61: ......

Страница 62: ...7745202 English 08 2005 ...

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