Volvo Penta TAD570VE Operator's Manual

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Operator's manual (96 pages)

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OPERATOR'S MANUAL

TAD570VE, TAD571VE, TAD572VE

TAD870VE, TAD871VE, TAD872VE, TAD873VE

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Page 1 OPERATOR’S MANUAL TAD570VE, TAD571VE, TAD572VE TAD870VE, TAD871VE, TAD872VE, TAD873VE...
Page 2 Veuillez contacter votre Distributeur Volvo Penta si vous Εάν δεν είναι δυνατή η πρόσβαση στο ιαδίκτυο,παρακαλούμε avez un problème d‘accès à l‘Internet. επικοινωνήστε με το δικό σας αντιπρόσωπο της Volvo Penta. El presente libro de instrucciones puede solicitarse Данное руководство по эксплуатации можно...
Page 3: Table Of Contents
Operation ....................24 Engine Shutdown ..................25 Fault Handling ................... 27 Fault Code Register .................. 36 Maintenance Schedule ................38 Maintenance ....................41 Storage ....................... 66 Technical Data ................... 68 Alphabetical index ..................75 47706299 11-2014 © AB VOLVO PENTA...
Page 4: Foreword
Foreword Volvo Penta engines are used all over the world. They are used in all possible operating conditions. This is not a coincidence. After 100 years as an engine manufacturer the Volvo Penta name has become a symbol of reliability, technical innovation, top-of-the-range performance and long service life.
Page 5: Safety Information
This chapter describes how safety precautions are presented in the Operator’s Manual and on the product. It also gives you an introduction to the basic safety rules for using and looking after the engine. If anything remains unclear or if you are unsure of something, contact your Volvo Penta dealer for assistance. IMPORTANT! Always follow local safety instructions and regulations.
Page 6 Never overfill the tank. Close the tank cap securely. Only use fuel recommended in the Operator’s man- ual. The wrong grade of fuel can cause serious mal- functions, power loss or engine shutdown. 47706299 11-2014 © AB VOLVO PENTA...
Page 7 Never carry out a job if you are not entirely sure how The lifting eyes fitted on the engine must be used for to do it. Contact your Volvo Penta dealer and ask for lifting. Always check that the lifting devices are in good assistance instead.
Page 8 Danger of personal injury. accordance with applicable legal requirements. Using spare parts other than those by Volvo Penta approved spare parts may cause an explosion or fire. Electrical System...
Page 9: Introduction
This Operator's Manual contains the information required for the correct, safe operation and maintenance of your Volvo Penta engine. Read the Operator’s manual carefully and learn to handle the engine and other equipment in a safe manner before you start the engine.
Page 10 This places special demands on the care and main- is a natural cornerstone of our product development. tenance you provide your engine, namely: Volvo Penta currently has a broad engine program in • Maintenance and service intervals recom- which great advances have been made in reducing mended by Volvo Penta must be complied with.
Page 11: Presentation
Presentation Engines This Operator’s Manual covers the following industrial diesel engines: TAD570VE, TAD571VE, TAD572VE, in-line, direct injected, 4-cylinder engines. TAD870VE, TAD871VE, TAD872VE, TAD873VE, in-line, direct injected, 6-cylinder engines. The engines are all equipped with electronic manage- ment (EMS), turbocharger, charge air cooler, thermo- statically controlled cooling systems and electronic speed control.
Page 12 EMS is an electronic system with CAN communication (Controller Area Network) for diesel engine control. The system has been developed by Volvo Penta and includes fuel regulation and diagnostic functions. The system consists of a control unit, injectors, a number of sensors that supply the control unit with information, and connectors for diagnostics and functional checks.
Page 13 For further information refer to EATS Inducements page 34 and Presentation page 11 . 47706299 11-2014 © AB VOLVO PENTA...
Page 14 9 EATS Catalyst and Muffler 10 Control unit (ACM), continuously monitors the EAT System. Activates the solenoid valve (3) at low temper- ature in the tank. 11 NOx sensor, measures level of NOx after the catalyst/muffler. 47706299 11-2014 © AB VOLVO PENTA...
Page 15 EATS sys- tem, as the remaining solution will circulate and cool the system. However, emissions from the engine will increase as the injection valve is closed and no exhaust aftertreatment will take place. 47706299 11-2014 © AB VOLVO PENTA...
Page 16 IMPORTANT! ® In the event of long-term storage, AdBlue /DEF solu- tion must not be stored at temperatures higher than 25 °C (77 °F) to prevent the breakdown and evapora- tion of the solution. 47706299 11-2014 © AB VOLVO PENTA...
Page 17 /DEF solution spillages may not be washed into drains. If a spill should occur, the solution must be absorbed using dry sand or other non-flammable material and handled according to local and national regulations. 47706299 11-2014 © AB VOLVO PENTA...
Page 18 — flush with copious amounts of water and remove contaminated clothing. • eye contact — flush thoroughly for several minutes; contact physician as necessary. • inhalation — breathe fresh air and contact physi- cian as necessary. 47706299 11-2014 © AB VOLVO PENTA...
Page 19: Instruments And Controls
Instruments and Controls Display Control Unit The Volvo Penta DCU II instrument panel communi- cates with the engine control unit and has a number of functions such as engine control, monitoring and diag- nostics. NOTICE! Settings and the type of engine data pre- sented on the display may vary depending on the installation and engine model.
Page 20 ALARM red text; the system has detected a serious fault – consult a Volvo Penta workshop immediately. • WARNING yellow text; the system has detected a fault – consult a Volvo Penta workshop as soon as possible. • MESSAGE blue text, non-critical engine message for the operator.
Page 21 . This will also provide information about the number of engine hours when the fault became active and the SPN and FMI codes. 47706299 11-2014 © AB VOLVO PENTA...
Page 22 Authorized Volvo Penta dealer or OEM only. The settings in the following menus do not normally need to be changed; should a change be necessary it must be carried out by an authorized Volvo Penta tech- nician. Refer to the installation manual for further engine information.
Page 23: Starting
Never break the circuit with the main switch while the engine is running, as this may damage the alter- nator. Move the engine speed control to idle, and open the • disengageable clutch/gearbox if installed. 47706299 11-2014 © AB VOLVO PENTA...
Page 24 Make sure the cooling system is filled with a glycol mixture. Refer to Maintenance page 53. • The batteries must be in good condition. Cold weather reduces battery capacity. Increased battery capacity may be necessary. 47706299 11-2014 © AB VOLVO PENTA...
Page 25 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 be loosened under any circumstances. 47706299 11-2014 © AB VOLVO PENTA...
Page 26: Operation
At low loads, the combustion temperature may become so low that complete combustion cannot be ensured, resulting in possible fuel dilution of lubricating oil and eventually leakage from the exhaust manifold. 47706299 11-2014 © AB VOLVO PENTA...
Page 27: Engine Shutdown
Extra Stop For location of the extra stop, please refer to Maintenance page 41. WARNING! Working with or approaching a running engine is a safety risk. Watch out for rotating components and hot surfaces. 47706299 11-2014 © AB VOLVO PENTA...
Page 28 If there is a risk of freezing, the coolant in the cooling system must have adequate antifreeze protection. Refer to the chapter Maintenance page 53. A poorly-charged battery can freeze and burst; refer to Battery, Charging page 65. 47706299 11-2014 © AB VOLVO PENTA...
Page 29: 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 diag- nostic tool. Depending on the severity of the fault, the diagnostic function will take various actions to protect the engine (e.g.
Page 30 If a malfunction has not been corrected it will be reg- istered once again and has to be acknowledged again. The Volvo Penta diagnostic tool VODIA must be used to erase a fault code. 47706299 11-2014 © AB VOLVO PENTA...
Page 32 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. NOTICE! Read through the safety advice for care and maintenance work in the chapter Safety Informa- tion page 3 before you start work.
Page 33 18 Faulty circulating pump 19 Defective thermostat 20 Blocked charge air cooler 21 Oil level too high 22 Alternator drive belt slips 23 High back pressure in the exhaust system 24 Break in ”Pot+” cable to throttle 47706299 11-2014 © AB VOLVO PENTA...
Page 34 Inducements page 34. NOTICE! Warning messages and symbols may vary depending on the installation; shown here are those seen on panels sold by Volvo Penta. Warning Symbols Stimulus for power reduction warning. A fault has been detected in the EATS system.
Page 35 AdBlue /DEF solution is connected. • that there are no leaks in the exhaust system where substantial amount of solution can escape. • that the EGR valve is not stuck. 47706299 11-2014 © AB VOLVO PENTA...
Page 36 3 x 30 minutes. After 30 minutes the engine drops to 50% power. Each 30-minute period requires a new manual activation. 6 If a fault recurs within 40 hours, available running time will be reduced to 120 minutes from the moment the fault is detected. 47706299 11-2014 © AB VOLVO PENTA...
Page 37 3 x 30 minutes. After 30 minutes the engine drops to 50% power. Each 30-minute period requires a new manual activation. 7 If a fault recurs within 40 hours, available running time will be reduced to 300 minutes from the moment the fault is detected. 47706299 11-2014 © AB VOLVO PENTA...
Page 38: Fault Code Register
Fuel Injector, Cylinder #5 3, 5 Fuel Injector, Cylinder #6 3, 5 Starter motor relay 3, 4, 5, 6 Preheat sense 1 5, 6, 7, 12 Engine stop switch 3, 4, 5, 11, 14 47706299 11-2014 © AB VOLVO PENTA...
Page 39 520689 EGR "A" / Volvo Compression Brake (VCB) Control Circuit 3, 4, 5 520690 EGR "A" Control / Engine Turbocharger Wastegate Actuator 1 Position 3, 5 520691 Torque Speed Control 1 Received With Errors 47706299 11-2014 © AB VOLVO PENTA...
Page 40: Maintenance Schedule
Maintenance Schedule Your Volvo Penta engine and its equipment are designed for high reliability and long life. It is built so as to have minimal environmental impact. If given preventive maintenance, according to the maintenance schedule, and if Volvo Penta original spares are used, these properties are retained and unnecessary malfunctions can be avoided.
Page 41 Drive Belts ● Air Filter, Tank Breather ● Air Filter, Compressor (Does not apply to all models.) ● AdBlue®/DEF filter (Does not apply to all models.) ● Turbocharger, inspect / clean as required ● 47706299 11-2014 © AB VOLVO PENTA...
Page 42 Maintenance Schedule Every 5000 hours At least every (month) EGR cooler Every 8000 hours / ● Coolant VCS (yellow) 1) Different types of coolant must not be mixed with each other. 47706299 11-2014 © AB VOLVO PENTA...
Page 43: Maintenance
This chapter describes the most common maintenance items, see Maintenance Schedule page 38 for service intervals. NOTICE! Service points which are not described here must be performed by an authorized Volvo Penta workshop. CAUTION! Read the chapter on Maintenance before starting work. It contains instructions on how to carry out maintenance and service operations in a safe and correct manner.
Page 44 Maintenance TAD870VE, TAD871VE, TAD872VE, TAD873VE 1 Fuel Filter 2 Oil filter 3 Auxiliary stop 4 Fuses 5 Oil filler cap, engine 6 Oil dipstick 7 Fuel pre-filter P0018945 47706299 11-2014 © AB VOLVO PENTA...
Page 45 Change as necessary. Check for leaks in the exhaust system. Leaks between the turbo and the muffler represent a risk for leakage of AdBlue/DEF solution. P0019781 47706299 11-2014 © AB VOLVO PENTA...
Page 46 Replacement 1 Remove the right belt guard. P0019257 2 Undo the belt tensioner and restrain it with a man- drel. Remove the old drive belt. P0019255 47706299 11-2014 © AB VOLVO PENTA...
Page 47 5 Re-install the belt guards. 6 Check that the belts are correctly aligned in their grooves and are correctly tensioned. It should be possible to depress the drive belt about 3-4 mm (0.12–0.16") between the pulleys. P0019256 47706299 11-2014 © AB VOLVO PENTA...
Page 48 Only use a recommended grade of oil; refer to Oil recommendations page 69. • Make sure that the oil level is between the MIN and MAX marks. Do not fill above the maximum oil level. P0019132 47706299 11-2014 © AB VOLVO PENTA...
Page 49 5 Start the engine and check that there is no oil leak- age from the oil filter or drain nipple. 6 Switch the engine off and check the oil level after a few minutes. Top up with oil as necessary. 47706299 11-2014 © AB VOLVO PENTA...
Page 50 7 Stop the engine. Check that there is no oil leakage around the filters. Check the oil level and top up with oil as necessary. Refer to Oil level, checking and topping up page 46. 47706299 11-2014 © AB VOLVO PENTA...
Page 51 Risk of material damage. Use only a fuel filter approved by the manufacturer. The wrong type of fuel filter may damage the fuel injection circuit. IMPORTANT! Working with the fuel system requests special cleanli- ness. 47706299 11-2014 © AB VOLVO PENTA...
Page 52 5 Remove the fuel pre-filter (4) and seal together with the lower section of the water separator (3). Put the used filter in a suitable container. 6 Clean the lower section of the water separator and the contact surfaces. P0019195 47706299 11-2014 © AB VOLVO PENTA...
Page 53 NOTICE! Put a collection vessel under the fuel filter to collect the condensate and fuel. 1 Remove the protective cap on the bleeder nipple (1). 2 Loosen the nipple, at least two turns. P0019233 47706299 11-2014 © AB VOLVO PENTA...
Page 54 NOTICE! Bleeding is not complete while resistance is felt in the pump. 8 Wait 15 seconds and then repeat step 7. 9 Fit the protective cap on the bleeding nipple. 47706299 11-2014 © AB VOLVO PENTA...
Page 55 The use of anti-corrosion agents alone is not permitted in Volvo Penta engines. Never use water alone as the coolant. The corrosion protection additives become less effec- tive over time, which means that the coolant must be changed at regular intervals;...
Page 56 The coolant must be mixed with distilled, deionized water. The water must fulfil the requirements specified by Volvo Penta; refer to Water Quality page 71. It is extremely important that the system is filled with the correct coolant concentration. Mix in a separate clean vessel before filling the cooling system.
Page 57 3 Open all drain points. Drain the coolant from the radiator and engine block, using the drain hose. The drain nipples are situated under the radiator on the right side of the engine block. 19140 47706299 11-2014 © AB VOLVO PENTA...
Page 58 55. 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 71 until the water draining out is com- pletely clear.
Page 59 8 When the cooling system is completely free from contamination, close the drain taps and plugs. 9 Fill up with Volvo Penta recommended coolant, fol- lowing the instructions in the chapters entitled Maintenance page 53 and Coolant Level, Checking and Topping Up page 54.
Page 60 If a spill should occur the solution must be absorbed using dry sand or other non-flammable material and handled according to local and national regulations. Avoid spills onto soil and into waterways. 47706299 11-2014 © AB VOLVO PENTA...
Page 61 • Injectors may be damaged • The engine will no longer fulfill emission level requirements • Corrosion in the exhaust system between the turbocharger and aftertreatment system • Expensive repairs • Expensive repairs 47706299 11-2014 © AB VOLVO PENTA...
Page 62 ® ing of the AdBlue /DEF hoses. Disconnect the battery negative terminal. P0019364 Place a receptacle under the filter cover. Undo the filter cover NOTICE! Use approved safety equipment and receptacle. P0019389 47706299 11-2014 © AB VOLVO PENTA...
Page 63 Pull out the filter. P0019390 Install the new filter (1). Install the rubber gasket (2). Screw on the filter cover (3). P0019391 47706299 11-2014 © AB VOLVO PENTA...
Page 64 Tightening torque: 20 (+5) Nm (14.8 +3.68 Ibf. ft.) P0019392 Reconnect the battery negative terminal. Start the engine. Check for leaks; check function. Delete any fault codes. P0019365 NOTICE! Care for equipment and the remaining AdBlue®/DEF solution. p0013225 47706299 11-2014 © AB VOLVO PENTA...
Page 65 A) and one for the ETA system (25 A). The engine stops if the fuse trips. If the fuse trips fre- quently, an authorized Volvo Penta workshop should be contacted to investigate the cause of the overload. Refer to Maintenance page 41 for location of the fuses.
Page 66 Top up with distilled water as required. After filling, the battery should be charged for at least 30 minutes by running the engine at idle. Some maintenance-free batteries have special instructions, which must be followed. P0016910 47706299 11-2014 © AB VOLVO PENTA...
Page 67 Batteries are damaged by being left discharged, and can also freeze and burst more easily in cold weather. Special instructions apply to boost charging. Boost • charging can shorten battery life, and should there- fore be avoided. P0002111 47706299 11-2014 © AB VOLVO PENTA...
Page 68: Storage
Because it is of utmost importance that the conservation be performed correctly, we have compiled a checklist covering the most important points. Before taking the engine out of service for long periods, it should be checked by a Volvo Penta dealer for possible need of overhaul or repair. CAUTION! Read the chapter on Maintenance before starting work.
Page 69 2/3 diesel fuel. • Drain the conservation oil from the engine. • Bleed the fuel system. • Follow the other instructions on the previous page. * Conservation oils are sold by oil companies. 47706299 11-2014 © AB VOLVO PENTA...
Page 70: Technical Data
No. of cylinders Bore 110 mm (4.33 inch) Stroke 135 mm (5.31 inch) Displacement 7,7 dm (470 in Weight, wet (engine only) 775 kg (1709 lb) Firing order 1-4-2-6-3-5 Compression ratio 17.5:1 Idling speed 47706299 11-2014 © AB VOLVO PENTA...
Page 71 NOTICE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality requirements above. VDS = Volvo Drain Specification Viscosity Select the viscosity according to the table. The temperature values refer to stable ambient tem- peratures. * SAE 5W/30 refers to synthetic or semi-synthetic oils. 47706299 11-2014 © AB VOLVO PENTA...
Page 72 Vegetable oil esters (Fatty Acid Methyl Esters, FAME), also called "biodiesel", are increasingly available as a blending component in diesel 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%.
Page 73 85 °C (185 °F) fully open at 95 °C (203 °F) Coolant Volvo Penta Coolant VCS and VCS Ready Mixed (yel- low) are based on Organic Acid Technology, OAT. IMPORTANT: Different types of coolant must not be mixed with each...
Page 74 Starter motor, output 5,5 kW (7.4 hp) Battery electrolyte specific gravity at +25 °C: fully charged battery 1.28 g/cm (1.24 g/cm battery recharged at 1.20 g/cm (1.20 g/cm Note! * Applies to batteries with tropical acid. 47706299 11-2014 © AB VOLVO PENTA...
Page 75 THIS ENGINE CONFORMS TO EU STAGE OF THE NON ROAD MOBILE MACHINERY DIRECTIVE 97/68/EC . EC TYPE-APPROVAL NUMBER : USE VOLVO SOFTWARE SERVICE TOOL TO VERIFY ACTUAL ENGINE SETTINGS. 18883 Country of manufacture. P0020083 47706299 11-2014 © AB VOLVO PENTA...
Page 77: Alphabetical Index
Identification Numbers..........73 Inlet and Exhaust System..........58 Main switch..............63 Maneuvering..............24 Never Use Start Spray..........23 Oil filter, Change............47 Oil recommendations..........69 Operation at low load..........24 Orientation..............41 Overview..............12 Quality shortcomings and component defects..33 47706299 11-2014 © AB VOLVO PENTA...

This manual is also suitable for:

Tad571ve Tad572ve Tad870ve Tad871ve Tad872ve Tad873ve

Volvo Penta TAD570VE Operator's Manual

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