Table of Contents
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Users guide and and maintenance
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Chapters
Table of Contents
Related Manuals for Volvo TAD941GE
Summary of Contents for Volvo TAD941GE
- Page 1 Users guide and and maintenance manual 7745269 (11-2005) 33522062701_1_1...
- Page 2 OPERATOR’S MANUAL Generating set and industrial engines 9 liter (EMS 2)
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Page 3: Table Of Contents
Before starting ........... 18 Effect on engine ..........49 Starting method EMS 2 ........19 Operation ............50 Volvo Penta starter switch ........20 Starting in extreme cold ........21 Fault codes ............51 Never use start spray ......... 22 Starting with auxiliary batteries ...... -
Page 4: Safety Information
If there is still something which is unclear or if you feel unsure about it, please con- tact your Volvo Penta dealer for assistance. This symbol is used in the instruction book and on the product, to call your attention to the fact that this is safety information. -
Page 5: Safety Rules For Operation And Maintenance
Never do a job if you are not entirely sure about how book. The wrong grade of fuel can cause malfunctions to do it. Please contact your Volvo Penta dealer and or stop the engine. In a diesel engine, it can also ask for assistance instead. - Page 6 Components in fuel systems and electrical systems ing. Always check that the lifting devices are in good on Volvo Penta engines are designed and manufac- condition and that they have the correct capacity for tured to minimize the risk of explosions and fire, in ac- the lift (engine weight together with auxiliaries, if fit- cordance with applicable legal requirements.
- Page 7 Safety information Chemicals Electrical system Most chemicals, such as glycol, rust preventer, con- Cut the current servation oils, degreasers etc. are hazardous. Always Before any work is done on the electrical system, the read and observe the advice on the packages. engine must be stopped and the current cut by switch- Some chemicals, such as conservation oils, are flam- ing off the main switch(es).
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Page 8: Introduction
Introduction This instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta industrial engine. It contains the information you need to be able to operate and maintain the engine safely and correctly. Please read the instruction book carefully and learn to handle the engine, controls and other equipment in a safe manner before you start the engine. -
Page 9: Certified Engines
AB Volvo Penta may fully or partly refuse to honor its warranty undertakings. Please contact your Volvo Penta dealer if you have not received a Warranty and Service book, or a customer copy of the warranty card. -
Page 10: Introduction
Introduction TAD940GE, TAD941GE, TAD940VE, TAD941VE, TAD942VE, TAD943VE, TAD950VE, TAD951VE and TAD952VE are in-line, direct injected, 6-cylinder industrial diesel engines. TAD950VE, TAD951VE have TAD952VE have internal EGR (Exhaust Gas Recirculation). All engines are equipped with electronically controlled fuel management (EMS 2), turbocharger, intercooler, ther- mostatically controlled cooling systems and electronic speed control. -
Page 11: Identification Numbers
Introduction Identification numbers Location of engine signs The sign above shows examples of: The sign above shows examples of: Engine designation Engine designation Serial number Engine power, net, (without fan) Specification number Max. engine speed Main software Data set 1 Data set 2 Product number Explanation of engine designation:... -
Page 12: Ems 2
Introduction EMS 2 EMS 2 (Engine Management System) 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 control and diagnostic function. Summary Fuel control... -
Page 13: Instrument, Ems 2
Introduction Instrument, EMS 2 NOTE! All instruments are accessories. CIU - Control Interface Unit The CIU is the “translator” between the EMS 2 control unit and the customer’s own control panel. The CIU has two serial communication links, a fast one and a slow one. -
Page 14: Dcu (Display Control Unit)
Introduction DCU (Display Control Unit) The DCU (Diesel Control System) control panel is available as an optional accessory for the EMS (Engine Man- agement System) electronic control system. The DCU is a digital instrument panel which communicates with the engine control unit. DCU has several functions, such as: engine control, monitoring, diagnostics and parameter setting. - Page 15 Introduction Menus There are several sub-menus under each main menu. There is not space for all the menu choices on the display. To scroll through the menus, use the “7” and “9” buttons on the display. Press the “SEL” button, no. “8”...
- Page 16 Introduction Preheat manual activation of pre-heating. When it is activated, the EMS system senses when started if pre-heating is needed. For automatic pre-heating, please refer to the “Setup” / “Pre-heat on ignition” menu. The pre-heating time is adjusted to suit the engine temperature, and can last for up to 50 seconds both before and after starting.
- Page 17 Introduction Setup parameter setting in the engine’s control systems. Dif- ferent menus appear under “Customer parameter”, de- pending on whether you select “Versatile” or “Genset” from “Set application”. The parameters that can be set / selected (choice is made with the SEL button) are: •...
- Page 18 Introduction Customer parameter / Genset • Primary engine speed - selection of engine speed, 1500 or 1800 rpm. • Preheat on ignition - activation of automatic pre- heating. The engine control system senses if pre- heating is needed and activates it directly when switched on.
- Page 19 Introduction Display setting settings for the display. Adjustment is done with the “7” and “9” buttons, please refer to the DCU panel in the illustration. • Set contrast (%) - display contrast adjustment. • Set backlight time (sec) - sets the time (in sec- onds) for background illumination in the display.
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Page 20: Starting The Engine
Starting the engine Make it a habit to give the engine and engine bay a visual check before starting. This will help you to discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments and warning dis- plays show normal values after you have started the engine. -
Page 21: Starting Method Ems 2
Starting the engine Starting method EMS 2 The pre-heating time is adjusted to suit the engine temperature, and can last for up to 50 seconds both before and after starting. The starter motor connection time is maximized to 30 seconds. After that, the starter motor circuit is cut for 80 seconds to protect the starter motor against over- heating. -
Page 22: Volvo Penta Starter Switch
Starting the engine Volvo Penta starter switch (standard pre-heating setting) 1. Turn the key to position “I” and check the warning lamps 2. Position “II”. Pre-heating is activated (pre-heating is optional). Wait until the pre-heating indication lamp goes out. Pre-heating time depends on en- gine temperature. -
Page 23: Starting In Extreme Cold
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. IMPORTANT! Make sure that the cooling sys- tem is filled with a glycol mixture. Please refer to the “Maintenance, cooling system”... -
Page 24: Never Use Start Spray
Starting the engine Never use start spray WARNING! Never use start spray or similar prod- ucts as a starting aid. They may cause an explo- sion in the inlet manifold. Personalinjury could also be caused. Starting with auxiliary batteries WARNING! Batteries (especially auxiliary batter- ies) contain hydrogen which is highly explosive in contact with air. -
Page 25: Operation
Operation Correct operation technique is very important for both fuel economy and engine life. Always let the engine warm up to normal operating temperature before operating at full power. Avoid sudden throttle openings and operation at high engine speeds. Operation at low load Checking instruments Avoid long-term operation at idle or at low load, since Check all instruments directly after starting, and then... -
Page 26: Stopping The Engine
Stopping the engine During longer breaks in operation, the engine must be warmed up at least once every fortnight. This prevents cor- rosion att acks in the engine. If you expect the engine to be unused for two months or more, it must be laid up: Please refer to the chapter entitled “Laying up”. -
Page 27: Maintenance Schedule
Maintenance schedule General Your Volvo Penta engine and its equipment are designed for high reliability and long life. It is built so as to have min- imal 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 28 Maintenance schedule Every 400 hours / at least every 12 months • Fuel tank (sludge trap), drain..............not shown • Drive belts, inspection ................page 28-29 • Batteries, checking the electrolyte level ............page 43 Every 800 hours / at least every 12 months •...
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Page 29: Maintenance
Maintenance This chapter describes how the specified maintenance points should be done. Read them carefully before starting work. The times when maintenance points need to be attended to are given in the previous chapter: Maintenance schedule. WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chap- ter before starting work. - Page 30 Maintenance Drive belt/Alternator belt, inspection Inspection should be done after operation, when the belts are hot. It should be possible to press the alternator belts and drive belts down about 3-4 mm (0.12-0.16") between the pulleys. The alternator belts and drive belts have automatic belt tensioners and do not need to be adjusted.
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Page 31: Air Filter Indicator, Inspection 1)
Maintenance Drive belt, changing 1. Disconnect the main switch(es) and check that the engine is not connected to system voltage. 2. Remove the protective grating and the outer fan ring round the cooling fan. 3. Remove the protective plates round the drive belts. -
Page 32: Lubrication System
Use oil with TBN 14-20. NOTE! 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 ACEA = Association des Constructeurs Européenne d’Automobiles = American Petroleum Institute... -
Page 33: Oil Level, Checking And Filling
Maintenance Oil level, checking and filling The oil level must be inside the marked area on the dipstick and must be checked daily before the first start. Top up with oil via the filler opening on the left side of the engine. -
Page 34: Oil Filter/By-Pass Filter, Change
Maintenance Oil filter/By-pass filter, change WARNING! Hot oil and hot surfaces can cause burns. 1. Clean the oil filter bracket. 2. Remove all oil filters with a suitable oil filter remover (1). 3. Clean the mating surface of the oil filter bracket. Make sure that no pieces of old oil seal are left behind. -
Page 35: Cooling System
The coolant should contain a good grade of ethylene glycol and a suitable chemical formula for full engine protec- tion. The use of only an anti-corrosion preparation is not permissible for use in Volvo Penta engines. Never use water by itself as the coolant. - Page 36 (at 60% glycol concentration, the freezing point is low- ered to -54°C (-65.2°F)). Never mix more than 60% con- centrate (Volvo Penta Coolant) in the coolant. This will give reduced frost protection and poorer cooling effect, with a consequent risk of overheating.
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Page 37: Coolant, Checking Level
Filling a completely empty system 1. Open filler cap (1). 2. Check that all drain points are closed. NOTE! Only use the coolant recommended by Volvo Penta. 3. Mix the correct amount of coolant in advance, to ensure that the cooling system is completely filled. - Page 38 Maintenance Coolant. Draining The engine must be stopped before draining, and the filler cap unscrewed. WARNING! Do not open the filler cap (1) when the engine is warm, except in emergencies. Steam or hot fluid could spray out. NOTE! Do not open filler cap (2). On engines which are to be laid up or put in storage, the engine cooling system should not be drained.
- Page 39 Maintenance Coolant filter, changing 1. Turn the tap (1) 90° to stop the flow through the coolant filter. 2. Remove the coolant filter with a suitable extractor. Make sure that no residue from the old seal re- mains in the housing. 3.
- Page 40 7. If contamination should still be left after a long pe- riod of flushing, you can do a clean-out with Volvo Penta radiator cleaner, followed by finishing-off with Volvo Penta neutralizer. Carefully follow the instructions on the package.
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Page 41: Fuel System
Maintenance Fuel system Only use the grades of fuel recommended in the fuel specification below. Always observe the greatest cleanliness during re-fueling and work on the fuel system. All work on the injection system of the engine must be done by an authorized workshop. WARNING! Fire hazard. -
Page 42: Primary Fuel Filter, Change
Maintenance Fuel filter, changing NOTE! 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. WARNING! The fuel filter must be changed when the engine is cold, to avoid the risk of fire due to spilled fuel on hot surfaces. -
Page 43: Primary Fuel Filter. Drain Water/Contamination
Maintenance Draining condensate, fuel system With mechanical drain nipple: 1. Open the drain nipple (1) in the base of the pri- mary fuel filter. NOTE! Put a collection vessel under the fuel filter, collect the condensate and fuel. 3. Press the electric feed pump switch until water- free fuel starts to run out. -
Page 44: Electrical System
Note. The engine stops if the fuse trips. If the circuit breaker trips frequently, an authorized Volvo Penta workshop should be contacted to investi- gate the cause of the overload. Electrical connections Check that electrical connections are dry, free from oxide and that they are securely tightened. - Page 45 Maintenance Battery. Maintenance WARNING! Fire and explosion hazard. Batteries must never be exposed to open flames or sparks. WARNING! Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion. WARNING! Battery electrolyte is highly corro- sive.
- Page 46 Maintenance Batteries, charging WARNING! Explosion risk! Hydrogen is given off when batteries are charged. This forms an explo- sive mixture with air. A short circuit, open flame or spark could cause a violent explosion. Ventilate well. WARNING! Battery electrolyte is highly corrosive. Protect your eyes, skin and clothes.
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Page 47: Component Location
NOTE! Please note that there are different loca- tions, depending on model. 14. Camshaft position sensor 7. Main relay 15. Oil pressure sensor 8. Diagnostic connector 16. Flywheel position and speed sensor 2-pin: TAD940-43VE, TAD940-TAD941GE 6-pin: TAD950-52VE 9. Fuel pressure sensor... -
Page 48: Laying Up
For this reason, we have compiled a check list of the most important points. Before the engine is taken out of service for a long period of time, an authorized Volvo Penta workshop should check it over. -
Page 49: Removing Conservation Preparations
Laying up Removing conservation preparations • Close the drain taps and install any draining plugs. • Remove any covers from the engine, air filter and • Check the coolant level. Top up as necessary. exhaust pipe. • Connect the fully charged batteries. •... -
Page 50: Fault Tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below. Always con- tact your Volvo Penta dealer if any problems occur which you can not solve by yourself. WARNING! Read through the safety advice for care and maintenance work in the chapter entitled “Safety- information”... -
Page 51: Diagnostic Function
Diagnostic function The diagnostic function monitors and checks that the EMS 2 system functions normally. The diagnostic function has the following tasks: • Discover and localize malfunctions • Notify that malfunctions have been discovered • Give advice in fault finding Fault code If the diagnostic function discovers a malfunction in •... -
Page 52: Operation
Operation Reading fault cause via the DU (Display When a malfunction has occurred and the diagnostic system has generated one or more fault codes, these Unit) are read out differently, depending on the equipment Depending on the severity of the faults, one of the fol- used. -
Page 53: Fault Codes
Reading fault codes via the diagnostic Reading fault codes via ”Easy Link” in- lamp on the instrument panel, CIU strument (only with CIU) When the system has discovered a malfunction, the When the system has discovered a malfunction, the diagnostic lamp starts to flash. If the diagnostic but- diagnostic lamp starts to flash and the fault code will ton is depressed and then released, a fault code is show in the display of the tachometer. - Page 54 Fault codes WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chap- ter before you start work. NOTE! Reading the fault codes below, such as Code 2.1. PID 97. means that 2.1 is the flashing code indicated by the diagnostic lamp on the instrument box.
- Page 55 Fault codes Code 2.5, SID22 / SPN 636 Code 2.9, PID / SPN 97, Indicator for water in fuel Camshaft drive speed sensor Cause: Cause: • Short circuit • No signal. • Open circuit. • Abnormal frequency. • Fault in indicator. •...
- Page 56 Fault codes Code 3.3, PID / SPN 110 Code 3.6, PID / SPN 94, Fuel pressure sensor Coolant temperature sensor Cause: Cause: • Short circuit to positive (+) or earth (ground) (–). • Short circuit to positive (+) or earth (ground) (–). •...
- Page 57 Fault codes Code 3.9, PID / SPN 158, Battery voltage, EMS Code 5.3, PPID 6/ SPN 970, Stop input CIU Cause: Cause: • Faulty alternator. • Short circuit to negative (-). • Faulty battery, battery cables. • Open circuit. Reaction: •...
- Page 58 Code 5.8, PID / SPN 175, Oil temperature Code 6.2, PID / SPN 105, Charge air temperature Cause: Cause: • Oil temperature is too high • Charge air temperature is too high. Reaction: Reaction: • Warning indication. • Engine control module reduces engine power (un- less the protection has been shut off with the •...
- Page 59 Fault codes Code 6.5, PPID 231 / SPN 639, Code 6.8, PPID 8 / SPN 520192, Data link (CAN), EMS 2 Piston cooling pressure sensor Cause: Cause: • Internal fault in control module. • Shorted to plus (+) or minus (-). Reaction: •...
- Page 60 Fault codes Code 7.1, SID 1 / SPN 651, Code 7.3, SID 3 / SPN 653 Injector, cylinder #1 Injector, cylinder #3 Cause: Cause: • Electrical fault. • Electrical fault. • Faulty compression or injector. • Faulty compression or injector. Reaction: Reaction: •...
- Page 61 Fault codes Code 7.5, SID 5 / SPN 655 Code 7.7, PID / SPN 153 Injector, cylinder #5 Crankcase ventilation pressure Cause: NOTE! Only TAD950-952VE. Cause: • Electrical fault. • Crankcase ventilation pressure too high. • Faulty compression or injector. Reaction: Reaction: •...
- Page 62 Fault codes Code 9.3, SID 232 / SPN 620 Code 9.8, PPID 254 / SPN 629 Power supply to sensor Fault in control unit, CIU Cause: Cause: • Shortcut. • Faulty EEPROM, CIU. • Fault in sensor. • Faulty flash memory, CIU. Reaction: •...
- Page 63 Fault codes Code 9.9, SID 254 / SPN 629 PPID 19 / SPN 2791, Internal EGR Control module EMS Cause: Cause: • Fault in cable harness (boost pressure sensor). • Internal fault in control module. • Mechanical fault on the IEGR Reaction: Reaction: •...
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Page 64: General
Technical data General Type designation TAD940GE TAD941GE Power, Prime/Stand-by Please refer to the sales literature Torque, Prime/Stand-by Please refer to the sales literature Compression ratio 20.2:1 17.4:1 Low idle (rpm) 600-1200 600-1200 High idle (rpm) 1500-1620 1500-1620 1800-1920 1800-1920 Highest full load speed (rpm) - Page 65 Technical data Type designation TAD950VE TAD951VE TAD952VE Power Please refer to the sales literature Torque Please refer to the sales literature Compression ratio 20.2:1 20.2:1 20.2:1 Low idle (rpm) High idle (rpm) 2250 2250 2250 No. of valves No. of cylinders Cylinder bore, mm (inch) 120 (4.72) 120 (4.72)
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Page 66: Technical Data
Technical data Lubrication system Oil, change volume, including filter change, .............. 35 liter (37.0 US quart) Oil pressure, hot engine, at operating speed TAD940-943VE, TAD940-941GE ..300-550 kPa (44-80 psi) TAD950-952VE ........350-600 kPa (51-87 psi) .............. at idle, min ..........270 kPa (39 psi) Oil grade .......... -
Page 67: Fuel System
Technical data Fuel system Feed pump Supply pressure at 600 rpm ....min 100 kPa (14.5 psi) Supply pressure at 1200 rpm ....min 300 kPa (43.5 psi) Supply pressure at full load ....min 300 kPa (43.5 psi) By - pass valve Opening pressure ......... -
Page 68: Cooling System
Technical data Cooling system Type ............Pressurized, sealed Pressure cap, max. opening pressure . 75 kPa (10.8 psi) Volume (engine) ........17 liter (17.9 US quart) Volume (engine + radiator and hoses) . 24 liter (25.3 US quart) Thermostat Quantity ..........1 pcs. - Page 69 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 70 Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 71 ✂ Yes please, I would like an operator’s manual in English at no charge. Publication number: 7745259 Post or fax this coupon to: Document & Distribution Cen- Name Order Department Address ARU2, Dept. 64620 SE-405 08 Göteborg Sweden Fax: +46 31 545 772 Orders can also be placed via the Internet: Country...
- Page 72 ✂ Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. Número de publicación: 7745263 Franquear o enviar fax a: Document & Distribution Cen- Nombre Order Department Direc- ARU2, Dept. 64620 ción SE-405 08 Göteborg Suecia Fax: +46 31 545 772 El pedido puede hacerse tam- bién por internet: País...
- Page 73 ✂ Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. Publicatienummer: 7745266 Stuur of fax de coupon naar: Document & Distribution Center Naam Order Department ARU2, Dept. 64620 Adres SE-405 08 Göteborg Zweden Fax: +46 31 545 772 U kunt ook bestellen via internet: http://www.volvopenta.com/...
- Page 74 ✂ Íáé, Èá Þèåëá Ýíá áíôßôõðï ôïõ åã÷åéñéäßïõ ÷ñÞóçò óôçí áããëéêÞ ãëþóóá ÷ùñßò êáìéÜ ÷ñÝùóç. Ôá÷õäñïìÞóôå áõôü ôï êïõðüíé Áñéèìüò Ýêäïóçò: 7745268 óôçí ðáñáêÜôù äéåýèõíóç Þ ¼íïìá óôåßëôå ôï ìå öáî óôïí ðáñáêÜôù áñéèìü öáî: Äéåýèõíóç Document & Distribution Center Order Department ARU2, Dept.
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