Related Manuals for Volvo Penta TAD550GE
Summary of Contents for Volvo Penta TAD550GE
- Page 1 Operator’s manual TAD550GE, TAD551GE TAD750GE, TAD751GE, TAD752GE, TAD753GE, TAD754GE...
- Page 2 WARNING! Operating, servicing and maintaining an engine can expose you chemi- cals including engine exhaust, carbon monoxide, phthalates, and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm. Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
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Page 3: Table Of Contents
Fuel, oils and coolant ................15 Maintenance and replacement parts ............16 Excessive strain on a product and components ........16 Environmental care ................. 17 Volvo Penta Dealer Network ..............19 Volvo Penta Action Service ..............19 Presentation ....................20 Engines ....................20 EMS (Engine Management System) ............ - Page 4 Technical Data ................... 75 Engines ....................75 Lubrication System ................76 Viscosity ....................76 Fuel System ................... 77 Cooling System ..................80 Water Quality ..................80 Electrical System .................. 81 Identification Numbers ................. 82 Index ......................85 47711096 09-2018 © AB VOLVO PENTA...
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Page 5: Foreword
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. -
Page 6: Safety Information
This chapter describes how safety precautions are If anything remains unclear or if you are unsure of presented in the manual and on the product. Read the something, contact your Volvo Penta dealer for chapter through very carefully before you start the assistance. - Page 7 WARNING! Ensure that all machine guards and safety devices are in place and are functional. P0024482 CAUTION! Never use tools or products that show signs of damage. 47711096 09-2018 © AB VOLVO PENTA...
- Page 8 Ensure that the workplace is well ventilated and take the necessary precautions before welding or grinding begins. Always ensure that there is a fire extinguisher close at hand in the work area. P0024470 47711096 09-2018 © AB VOLVO PENTA...
- Page 9 Spare parts — safety WARNING! Always use spare parts with the same quality as genuine Volvo Penta parts to minimize the risk of an explosion or fire. Components in fuel systems and electrical systems on Volvo Penta engines are designed and manufactured to minimize the risk of explosions and fire, in accordance with applicable legal requirements.
- Page 10 Prohibition on use of start spray WARNING! Never use start spray or similar agents to start an engine. This may cause an explosion in the inlet manifold. Risk of personal injury. P0024483 47711096 09-2018 © AB VOLVO PENTA...
- Page 11 The alternator and electronics could be damaged. Avoid damage to the engine control module and other electronics IMPORTANT: Switch off the main switch before connecting or disconnecting a connector. 47711096 09-2018 © AB VOLVO PENTA...
- Page 12 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. 47711096 09-2018 © AB VOLVO PENTA...
- Page 13 Safety Information 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. P0024477 WARNING! Risk of personal injury.
- Page 14 Layout of the battery compartment IMPORTANT: Make sure the battery compartment is designed according to current safety standards. Cleaning the engine and components IMPORTANT: Never use a high pressure washer for cleaning of engine or engine components. P0024486 47711096 09-2018 © AB VOLVO PENTA...
- Page 15 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. 47711096 09-2018 © AB VOLVO PENTA...
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Page 16: Introduction
Warranty Your new Volvo Penta engine is covered by a limited warranty, subject to the conditions compiled in the Warranty Information. Note that AB Volvo Penta’s liability is limited to the specification in the Warranty Information (included CD) and Emission Control System Warranty Statement. -
Page 17: Fuel, Oils And Coolant
Make sure to always use suitable and correctly mixed coolant. Future warranty claims related to engine and accessories may be denied if an unsuitable coolant has been used, or if the instructions for coolant mixture have not been followed. 47711096 09-2018 © AB VOLVO PENTA... -
Page 18: Maintenance And Replacement Parts
These qualities will be maintained through regular servicing and the use of spare parts with the same quality as genuine Volvo Penta parts. If reliable and purpose-built parts are not used, your safety, health, and the machine’s function may be compromised. -
Page 19: Environmental Care
Introduction Environmental care Environmental care is a core value at Volvo Penta. Energy efficiency and low emissions are among the most important product related aspects and priority focus areas for Volvo Penta business. Several of the global challenges the world faces are directly or indirectly related to power industries and transports. - Page 20 NOTICE! Neglects or failure to follow the points listed here may invalidate the engine emission certificate. This means AB Volvo Penta can no longer guarantee engine conformity with the certified model. Volvo Penta is not responsible for damages or costs arising as a result of this.
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Page 21: Volvo Penta Dealer Network
The Volvo Penta global network of authorized dealers is at your service. We strongly recommend that you take your product to an authorized Volvo Penta dealer for service and repair. They are specialists in Volvo Penta products and have the accessories, genuine... -
Page 22: Presentation
Presentation Engines This Operator's Manual refers to TAD550GE, TAD551GE, TAD750GE, TAD751GE, TAD752GE, TAD753GE, and TAD754GE industrial engines. These engines are in-line, direct injected 4-cylinder and 6-cylinder diesel engines. The engines are equipped with common rail fuel injection systems, electronically controlled fuel management (EMS 2), turbochargers, thermostatically controlled cooling systems and electronic speed control. -
Page 23: Ems (Engine Management System)
The control module uses the input signals to control the following components: unit injectors starter motor main relay pre-heating relay MPROP, high pressure fuel pump 47711096 09-2018 © AB VOLVO PENTA... -
Page 24: Instruments And Controls
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. 47711096 09-2018 © AB VOLVO PENTA... - Page 25 Scroll downwards in menus SPEED - . Reduces engine rpm SEL. Selects in menus SPEED +. Increases engine rpm Scroll upwards in menus STOP. Stops the engine 10 ESC. Return to previous menu selection 47711096 09-2018 © AB VOLVO PENTA...
- Page 26 Coolant temperature (°C) • Charge air temperature (°C) • Oil pressure (kPa) • Oil temperature (°C) • Engine hours (h) • Battery voltage (V) • Fuel consumption (l/h) • Instantaneous fuel consumption (trip fuel) (l) 47711096 09-2018 © AB VOLVO PENTA...
- Page 27 The fault codes are shown as text on the display. • Scroll through the fault list with the arrow keys. Trip Data reset resets trip data, such as fuel consumption. • Press the SEL button to reset trip data 47711096 09-2018 © AB VOLVO PENTA...
- Page 28 For activation, refer to Governor droop in the main menu. • Oil temp warning limit (°C) - setting alarm limit for oil temperature. • Coolant temp warning limit (°C) - setting alarm limit for coolant temperature. 47711096 09-2018 © AB VOLVO PENTA...
- Page 29 (accelerator). ext voltage input - engine rpm is controlled by an external unit. • Set idle voltage (V) - idle voltage level setting. • Set max voltage (V) - full throttle voltage level setting. 47711096 09-2018 © AB VOLVO PENTA...
- Page 30 DCU hardware Id - DCU part number. • DCU software Id - DCU software part number. • DCU dataset1 Id - DCU data set 1 part number. • DCU dataset2 Id - DCU data set 2 part number. 47711096 09-2018 © AB VOLVO PENTA...
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Page 31: Du (Display Unit)
In the display modes Engine, Trip and Graph, it is possible to adjust the contrast. Press button 5 outside the menu and then + (button 4) or – (button 3) to adjust the contrast. 47711096 09-2018 © AB VOLVO PENTA... - Page 32 The information is shown as graphs. Press button 4 repeatedly to choose what information will be shown. The time interval is set in the Configuration menu. If the connection is broken there will be a straight line in the display. 47711096 09-2018 © AB VOLVO PENTA...
- Page 33 - 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) 47711096 09-2018 © AB VOLVO PENTA...
- Page 34 EEPROM – number of write on EEPROM VERS – software version number CHK – Flash memory checksum PART No – Volvo software part number SOURCE – source of received data LABLE – Allocated Label on the same bus. 47711096 09-2018 © AB VOLVO PENTA...
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Page 35: Ciu (Control Interface Unit)
- Tachometer / hours counter (fault codes are also displayed on the tachometer display when the diagnostic button is pressed) - Coolant temperature - Oil pressure - Oil temperature - Battery voltage - Alarm panel - Turbo pressure 47711096 09-2018 © AB VOLVO PENTA... -
Page 36: Starting
Never break the circuit with the main switch while the engine is running. Alternator and electronics could be damaged. • Move the engine speed control to idle, and open the disengageable clutch/gearbox if installed. 47711096 09-2018 © AB VOLVO PENTA... -
Page 37: Starting The Engine
4 In the Preheat menu, press the SEL button (7) to select pre-heating; the text “Preheat active please wait” is shown in the display. 5 Wait until the text disappears and then press the START button (2). 47711096 09-2018 © AB VOLVO PENTA... -
Page 38: Starting In Extreme Cold
Make sure the cooling system is filled with a coolant mixture. Refer to Maintenance, page 65. • The batteries must be in good condition. Cold weather reduces battery capacity. Increased battery capacity may be necessary. 47711096 09-2018 © AB VOLVO PENTA... -
Page 39: Never Use Start Spray
Risk of arcing. Do not bend over any of the batteries either. 4 Remove the cables in the reverse order. IMPORTANT: The ordinary cables to the standard batteries must not under any circumstances be loosened. 47711096 09-2018 © AB VOLVO PENTA... -
Page 40: Operation
This is done by means of CAN signals to the instrument. More information about fault codes and fault tracing can be found in the chapter Fault handling, page 43. 47711096 09-2018 © AB VOLVO PENTA... -
Page 41: Maneuvering
Avoid load levels below 20% as constant operation. • If the engine is regularly tested without load, limit the duration of the operation to 5 minutes. Run the engine at full load for about 4 hours once a year, for 47711096 09-2018 © AB VOLVO PENTA... - Page 42 • If visible slobber has occurred, it can be burned off by running the engine on at least 30% load for about 40-60 minutes. 47711096 09-2018 © AB VOLVO PENTA...
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Page 43: Engine Shutdown
This is in order to save engine data to the engine control unit. Stop the Engine • Disengage the clutch (if possible). • Press the STOP button (5) / turn the key to S. P0008963 47711096 09-2018 © AB VOLVO PENTA... -
Page 44: Auxiliary Stop
"routine" stop button. After Engine Shutdown • Check the engine and engine bay for leakage. • Turn off the main switches before any long stoppage. • Carry out maintenance in accordance with the maintenance schedule. P0002078 47711096 09-2018 © AB VOLVO PENTA... -
Page 45: Fault Handling
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. Fault codes can also be read out by the Volvo Penta diagnostic tool. Depending on the severity of the fault, the diagnostic function will take various actions to protect the engine and limit emissions (e.g. -
Page 46: Ciu (Control Interface Unit)
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. 47711096 09-2018 © AB VOLVO PENTA... -
Page 47: Easy Link Instruments
If a malfunction has not been corrected it will be registered once again and has to be acknowledged again. The Volvo Penta diagnostic tool VODIA must be used to erase a fault code. 47711096 09-2018 © AB VOLVO PENTA... -
Page 48: Fault Tracing
Fault Tracing A number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer if any problems occur which you cannot solve by yourself. IMPORTANT: Read through the instructions for care and maintenance in before starting work. - Page 49 21 Blocked charge air cooler 22 Oil level too high 23 Alternator drive belt slipping 24 Water entry into engine 25 High back pressure in exhaust system 26 Break in “Pot+” cable to pedal 47711096 09-2018 © AB VOLVO PENTA...
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Page 50: Maintenance Schedule
Maintenance Schedule Your Volvo Penta engine and its equipment are designed for high reliability and long life. The engines are built to have the smallest possible environmental impact. If given preventive maintenance, according to the maintenance schedule, these qualities will be retained and unnecessary malfunctions will be avoided. In order for the warranty to be valid, the owner must make sure that the services in the service intervals are performed. -
Page 51: Maintenance
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 parts, always specify the engine and transmission identification number. Refer to Technical Data, page 82. 47711096 09-2018 © AB VOLVO PENTA... -
Page 52: Orientation
6 Oil filter 7 Oil dipstick, engine 8 Oil cooler 9 High-pressure pumps 10 Common rail-unit, with safety valve and rail- pressure sensor 11 Crankcase ventilation 12 Air filter indicator 13 Starter motor 14 Turbo 47711096 09-2018 © AB VOLVO PENTA... - Page 53 7 Oil cooler 8 Oil filter 9 Oil dipstick 10 Fuel pre-filter 11 Fuel Filter 12 Common rail-unit, with safety valve and rail- pressure sensor 13 High-pressure pumps 14 Starter motor 15 Turbo P0014482 47711096 09-2018 © AB VOLVO PENTA...
- Page 54 6 Oil filter 7 Oil dipstick 8 Auxiliary stop 9 Common rail-unit, with safety valve and rail- pressure sensor 10 Fuel Filter 11 High-pressure pumps 12 Crankcase ventilation 13 External EGR 14 Starter motor 15 Turbo 47711096 09-2018 © AB VOLVO PENTA...
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Page 55: Engine, General
Charge Air Pipe, Leakage Check Inspect the condition of the charge air hoses, hose unions and clamp condition for cracks and other damage. Change as necessary. Drive belt, check and change TAD550GE, TAD551GE, TAD750GE, TAD751GE IMPORTANT! 47711096 09-2018 © AB VOLVO PENTA... - Page 56 1 Loosen the screws 1, 2 and 3. 2 Remove the old drive belt. 3 Fit the new drive belt. P0014512 4 Adjusting screw, 4, until the proper belt tension is obtained 5 Retighten the screws 1, 2 and 3. 47711096 09-2018 © AB VOLVO PENTA...
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Page 57: Drive Belt, Check And Change
Remove the belt from the coolant pump (2) first. Install the new belt. Remove the belt tensioner and the drift (1). Check that the belts are correctly aligned in their grooves and are correctly tensioned. P0008974 47711096 09-2018 © AB VOLVO PENTA... -
Page 58: Lubrication System
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 dealer for further information. NOTICE! Oil change intervals must never exceed a period of 12 months. -
Page 59: Oil Filter, Change
5 Stop the engine. Check that no oil leakage occurs around the filters. Top up with oil as necessary. NOTICE! Collect the old oil and old filters and hand them toa re-cycling station for destruction. 47711096 09-2018 © AB VOLVO PENTA... -
Page 60: Oil Filter, Change
Check that there is no oil leakage from the oil filter P0008977 or drain nipple. • Turn off the engine. • Check the oil level after a few minutes. • Top up with oil as necessary. 47711096 09-2018 © AB VOLVO PENTA... -
Page 61: Engine Oil, Change
Start the engine and let it idle. Check that the oil pressure is normal. Stop the engine. Check that there is no oil P0008966 leakage around the filters. Top up with oil as necessary. 47711096 09-2018 © AB VOLVO PENTA... -
Page 62: Fuel System
5 Clean the reservoir and screw it back onto the filter cartridge. 6 Close the drain valve and open the fuel tap. 7 Purge the fuel system; refer to Fuel system, bleeding. Test run the engine and check that no leakage occurs. 47711096 09-2018 © AB VOLVO PENTA... -
Page 63: Engine Fuel Filter Replacement
4 Install a new filter and a new O-ring. 5 Purge the fuel system according to Fuel system, bleeding. 6 Warm up the engine and perform a function check in respect of any leakages. 47711096 09-2018 © AB VOLVO PENTA... -
Page 64: Engine Fuel Filter Replacement
Open the cock on the return line and remove the collection vessel. Purge the fuel system according to the method, Fuel system, bleeding. Warm up the engine and perform a function check in respect of any leakages. P0008973 47711096 09-2018 © AB VOLVO PENTA... -
Page 65: Fuel Pre-Filter, Change
Install the lower part of the water separator (2). NOTICE! Use a new seal ring. Open the fuel taps and purge the fuel system; refer to Fuel system, bleeding. Start the engine and check for leaks. P0008971 47711096 09-2018 © AB VOLVO PENTA... -
Page 66: Fuel System, Bleeding
Close the hand pump (1) by pressing it in and turning it clockwise. Start the engine and let it idle for at least 5 minutes, before speed is increased. 47711096 09-2018 © AB VOLVO PENTA... -
Page 67: Cooling System
- 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... -
Page 68: Coolant Level, Checking And Topping Up
Coolant Level, Checking and Topping Up NOTICE! Check the coolant level daily before starting. Only use coolant recommended by Volvo Penta. (2”) 1 Check that the coolant level is approx. 5 cm (2") under the top of the filler. -
Page 69: Coolant Level, Checking And Topping Up
Steam or hot fluid could spray out. IMPORTANT! Only use coolant recommended by Volvo Penta. Fill up slowly, to allow the air to flow out. NOTICE! Filling should only be done with the engine stationary. -
Page 70: Coolant, Draining
IMPORTANT! Check that all coolant poors out. Deposits may be located inside the tap / plug that must be eliminated. Remaining coolant in he system is a risk and can cause severe damage. P0014505 47711096 09-2018 © AB VOLVO PENTA... -
Page 71: Coolant, Draining
Check that all coolant has indeed drained out. Screw the drain plug (1) back. Remove the hose from the drain nipple (2) and put its protective cap back on. P0014519 47711096 09-2018 © AB VOLVO PENTA... -
Page 72: Charge Air Cooler, External Cleaning
1 Empty the cooling system. Refer to Coolant, Draining, page 68. 2 Put a hose into the expansion tank filling hole and flush with clean water, as specified by Volvo Penta– refer to section Water quality in Technical Data, page 80 until the water draining out is completely clear. - Page 73 8 When the cooling system is completely free from contamination, close the drain taps and plugs. 9 Fill up with Volvo Penta recommended coolant, following the instructions in the chapters entitled Maintenance, page 65 and Coolant Level, Checking and Topping Up, page 66.
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Page 74: Electrical System
Always stop the engine and break the current using the main switches before working on the engine. IMPORTANT: Contact a Volvo Penta dealer for information if any arc welding will be performed on the application. Arc welding can cause damage to the engine and the electronics. -
Page 75: Battery
• Charge the battery regularly. A battery that is kept fully loaded has a maximum service life. The easiest way to check if a battery needs charging is to use a voltmeter. 47711096 09-2018 © AB VOLVO PENTA... - Page 76 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 the nut. NOTICE! Hand in the old battery to a re-cycling station. 47711096 09-2018 © AB VOLVO PENTA...
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Page 77: Technical Data
(436 in Weight, Engine 780 kg (1720 lbs) 780 kg (1720 lbs) Weight, incl. cooling system and air filter 955 kg (2105 lbs) 955 kg (2105 lbs) Firing order 1-5-3-6-2-4 1-5-3-6-2-4 Compression ratio 18:1 17:1 47711096 09-2018 © AB VOLVO PENTA... -
Page 78: Lubrication System
API = American Petroleum Institute Global TBN = Total Base Number Viscosity Select the viscosity according to the table. The temperature values refer to stable ambient temperatures. * SAE 5W/30 refers to synthetic or semi-synthetic oils. 47711096 09-2018 © AB VOLVO PENTA... -
Page 79: Fuel System
Extremely low sulfur content fuel (urban diesel in Sweden and city diesel in Finland) can cause a loss of up to 5% of power and an increase in fuel consumption of about 2–3 %. 47711096 09-2018 © AB VOLVO PENTA... - Page 80 Sufficient fuel lubricity is essential to protect the fuel injection system against excessive wear. Restrictions for other diesel fuels Volvo Penta also approves the use of other diesel fuels as long as the here specified restrictions are followed. However Volvo Penta does not guarantee compliance with emission legislation or fulfillment of expected lifetime with these other diesel fuels.
- Page 81 Alternative fuels, including biodiesel, that are not substantially similar to the required test fuels may adversely affect engine emissions compliance. As a result, Volvo Penta does not warrant the engine will conform to applicable emissions limits when operated on, or having been operated on, biodiesel or other alternative fuels that are not substantially similar to specified test fuels used for certification.
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Page 82: Cooling System
98 °C (208 °F) 98 °C (208 °F) 103 °C (217 °F) Coolant Volvo Penta Coolant VCS and VCS Ready Mixed (yellow) are based on Organic Acid Technology, OAT. IMPORTANT! Different types of coolant must not be mixed with each other. -
Page 83: Electrical System
Technical Data Electrical System TAD550–51GE TAD750–51GE TAD752–54GE System voltage Alternator Voltage/max. current 28V/55A 28V/55A 28V/100A 47711096 09-2018 © AB VOLVO PENTA... -
Page 84: Identification Numbers
15 Valve clearance, inlet valvel (mm /slag ) Serial number (10 didgits) 16 Valve clearance, exhaust valve (mm /slag) Engine specification number 17 EP code for injection pump (cyl 1 först) Engine Speed 18 Further information 47711096 09-2018 © AB VOLVO PENTA... - Page 85 P0003292 Engine data (refer to engine plate below) Engine model (1): ..........................Specification number (2): ..........................Serial number (3): ..........................Nearest Volvo Penta workshop Name: ..........................Address: ..........................Telephone: ..........................47711096 09-2018 © AB VOLVO PENTA...
- Page 86 Applied standards: EN 61000–6–1, EN 6100–6–2, EN 61000–6–3, EN 61000–6–4, EN 12895, EN-ISO 14982 and EN 13309. For engines equipped with the Volvo Penta Start/Stop System the responsibility for the functional safety of the system lies with the machine manufacturer performing the integration.
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Page 87: Index
Maneuvering..............39 Never Use Start Spray..........37 Oil filter, Change..........57, 58 Oil level, checking and topping up......56 Operation at low load..........39 Orientation..............50 Reading the Instruments........... 38 Starting in Extreme Cold........... 36 Starting the Engine............35 47711096 09-2018 © AB VOLVO PENTA... - Page 89 من الممكن طلب دليل المشغل بلغة أخرى مجا ن ً ا عبر اإلنترنت لفترة تصل إلى 21 شهر ً ا من بعد .التسليم /http:// manual.volvopenta.com/coupon .Volvo Penta إذا كان الوصول إلى اإلنترنت غير متاح، فالرجاء االتصال بوكيل © 2018 AB VOLVO PENTA Volvo reserves the right to make changes...
- Page 90 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...