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Industrial engines
12 liter (EMS 2)
OPERATOR’S MANUAL
Engine data
Engine designation ........................... Product number ....................................
Serial number .........................................................................................................
Clutch, type/nr. .......................................................................................................
Nearest Volvo Penta service location
Name .......................................................................... Telephone ....................
Address ...................................................................................................................
© 2007 AB VOLVO PENTAVolvo reserves the right to make changesPrinted on environmentally friendly paper
ForewordVolvo Penta industrial engines are relied upon throughout the world,in both mobile and stationary applications, under some of the mostrigorous conditions imaginable. This is not by chance.
After more than 90 years of producing engines the name Volvo Pentahas come to symbolize reliability, technical ingenuity, first-class perfor-mance and longevity. We believe that these characteristics are alsoultimately your requirements and expectations for new Volvo Pentaindustrial engines.
To make certain that your expectations are matched, we ask thatyou read carefully through the instruction book before startingthe engine.
Sincerely
AB VOLVO PENTA
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Safety information .................................................. 2Safety instructions for operation andmaintenance ......................................................... 3
Introduction ............................................................ 6Environmental care ............................................... 6Running-in ............................................................. 6Fuel and oils ......................................................... 6Maintenance and replacement parts ...................... 6Certified engines ................................................... 7Warranty ............................................................... 7
Presentation ........................................................... 8Technical description ............................................ 8Identification numbers ........................................... 9Orientation .......................................................... 10Location of sensors ............................................. 11Instrument, EMS 2 .............................................. 14DCU (Display Control Unit) .................................. 15
Starting the engine ............................................... 21Before starting .................................................... 21Starting procedure EMS 2 ................................... 22Volvo Penta start lock ......................................... 23Start-up under extreme cold ................................ 24Never use starting spray ..................................... 25Start with booster batteries ................................. 25
Operation .............................................................. 26Checking instruments ......................................... 26Fault indication .................................................... 26Operation at low load .......................................... 26
Stopping the engine ............................................ 27Before shutdown ................................................. 27Stop .................................................................... 27After shutdown .................................................... 28Extra stop ........................................................... 28
Contents
Maintenance schedule ......................................... 29
Maintenance ......................................................... 31Engine, general ................................................... 31Lubrication system .............................................. 34Cooling system ................................................... 37Fuel system ........................................................ 43Electric system ................................................... 46
Preparations for storage ...................................... 49Conservation ....................................................... 49Removing conservation preparations ................... 50
Troubleshooting ................................................... 51Symptoms and possible causes ......................... 51
Diagnostic function .............................................. 52Message regarding disturbance ........................... 52Effect on engine .................................................. 52Operation ............................................................ 53
Fault codes ........................................................... 55
Technical data ...................................................... 64General ............................................................... 64Lubrication system .............................................. 64Fuel system ........................................................ 65Cooling system ................................................... 65Electric system ................................................... 66
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known tothe State of California to cause cancer, birth defects, and otherreproductive harm.
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Safety informationRead this chapter very carefully. It concerns your safety .How safety information is presented in the instructionbook and on the product is described here. You will also find an overall picture of the basic safety procedures foroperation of the engine.
Make sure that you have the correct instruction book before reading any further. If you do not, please con-tact your Volvo Penta dealer.
Incorrect operation can lead to injuries and/or product or property damage. It is therefore impor-tant to read through the instruction book very carefully before you start the engine or performmaintenance or service work. If there is anything that you are unclear on or unsure about even af-ter reading the book, please contact your Volvo Penta dealer for assistance.
This symbol is used in the instruction book and on the product to let you know that it con-cerns safety information. Always read this information very carefully.
In the instruction book warning texts are handled according to the following priority system:
WARNING! Warns of risk of injury, extensive damage to the product or other property, orthat serious functional problems can occur if the instruction is not followed.
IMPORTANT! Used to call attention to things that can cause damage or functionalproblems to the product or property.
NOTE!Used to call attention to important information that can make the work process or opera-tion go more smoothly.
This symbol is used in certain cases on our products and refers to important information inthe instruction book. Make sure that warning and information symbols on the engine and trans-mission are always visible and legible. Replace symbols that have been damaged or paintedover.
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Safety information
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Starting lockIf the instrument panel does not have a key switchthe engine compartment should be lockable to pre-vent unauthorized personnel from starting the engine.A lockable main switch may be used as an alterna-tive.
Maintenance and servicetasks
Knowledge
In the instruction book you will find instructions forhow the most common maintenance and servicetasks can be carried out in a safe and correct man-ner. Read the instructions carefully before initiatingwork.
Literature covering more extensive work is availablefrom your Volvo Penta dealer.
Never attempt a procedure if you are not completelycertain regarding how it should be performed. Contactyour Volvo Penta dealer for assistance.
Shut down the engine
Shut down the engine before opening or removing theengine access panel/hood. Maintenance and serviceprocedures should be carried out on a stopped en-gine unless otherwise specified.
Prevent an undesired start-up by removing the start-ing key and disconnecting the electricity with themain switch and locking it in the disconnected posi-tion. A warning notice should also be placed at theoperating station advising that work is being carriedout.
Working with or getting close to a running engine is asafety risk. Hair, fingers, loose-fitting clothing or adropped tool can get caught in rotating parts causingsevere injury. Volvo Penta recommends that all ser-vice work that requires that the engine be running beassigned to an authorized Volvo Penta repair facility.
Safety instructions for operation and maintenance
Daily checksMake a habit of always visually checking the engineand engine compartment prior to operation (beforestarting the engine) and after operation (after shut-ting down the engine). This will help you to quicklynotice if fuel, coolant or oil leaks or any other abnor-mal conditions have occurred or are occurring.
Fuel fillingThere is a risk of fire and explosion when filling tankswith fuel. Smoking is forbidden and the engine mustbe stopped.
Never overfill the tank. Make sure that the cap is cor-rectly closed.
Use only the fuel recommended in the instructionbook. Fuel of the wrong grade can cause the engine torun incorrectly or not at all. On a diesel engine it canalso lead to seizure of the injection system and over-revving the engine, putting both the machine and near-by people at risk.
Carbon monoxide poisoningOnly start the engine in a well-ventilated space. Dur-ing operation in an enclosed space both exhaust andcrankcase gases must be properly vented.
OperationThe engine should not be operated in environmentswith surrounding explosive substances due to the factthat the electrical and mechanical components cancause sparks.
Getting close to a running engine is a safety risk.Hair, fingers, loose-fitting clothing or a dropped toolcan get caught in rotating parts causing severe injury.
If the engine has been delivered without protectivecoverings, all rotating parts and hot surfaces shouldbe covered as necessary following installation to in-sure personal safety.
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Safety instructions for operation and maintenance (cont.)
Lifting the engine
When lifting the engine use the lifting eyes that aremounted on the engine. Always make sure that thelifting device is in good condition and has sufficientcapacity for the lift (the weight of the engine as wellas all necessary extra equipment). For safe handlingthe engine should be lifted with an adjustable liftingboom. All chains or cables should run parallel to eachother and as possible at right angles to the upper sur-face of the engine. Note that extra equipment that ismounted on the engine can change its center of gravi-ty. Special lifting equipment may be necessary to in-sure correct balance and safe handling. Never performwork on a motor that is only hanging in a lifting de-vice.
Before starting
Reinstall all protective covers that have been removedprior to starting the engine. Make sure that no tools orother objects have been left near the engine.
An engine with a turbocharger may never be startedwithout the air filter being mounted. The rotating com-pressor wheel in the turbo can cause severe injuries.There is also a risk that foreign objects can be suckedin causing damage to the machine.
Fire and explosionFuel and lubricating oil
All fuels, most lubricating substances and manychemicals are flammable. Always read and follow allinstructions listed on the packaging.
Work on the fuel system must be performed on a coldengine. Fuel leakage and spillage onto hot surfaces orelectrical components can cause a fire.
Store oil and fuel-soaked rags and other flammablematerial in a fire-safe manner. Oil-soaked rags canspontaneously ignite under certain conditions.
Never smoke while filling with fuel or lubricating oil, inproximity to the filling station or in the engine compart-ment.
Non-original parts
Components of the fuel and electrical systems on Vol-vo Penta engines are designed and manufactured tominimize the risk of explosion or fire according to ap-plicable requirements.
Use of non-original parts can result in explosion orfire.
Batteries
Batteries contain and develop oxyhydrogen gas, espe-cially while charging. Oxyhydrogen gas is easily flam-mable and very explosive.
Smoking, open fire or sparks must never be allowednear batteries or the battery compartment.
An improper connection of a battery cable or boostercable can cause a spark that can in turn cause thebattery to explode.
Starting fluid
Never use starting spray or other similar substancesto help start an engine with air preheating (glow plugs/starting coil). This could cause an explosion in the in-take tract. This poses a risk of injury.
Hot surfaces and fluidsA warm engine always creates a risk for burns. Becareful of hot surfaces. For example: exhaust pipes,turbo, oil sump, turbo pressure pipe, heating coil, hotcoolant and warm lubricating oil in lines and hoses.
ChemicalsMost chemicals, for example glycol, rust preventionsubstances, preserving oils, degreasers, etc. are haz-ardous to your health. Always read and follow the di-rections on the packaging.
Certain chemicals, for example preserving oils areflammable and also hazardous if inhaled. Make surethat you have good ventilation and use a protectivemask when spraying. Always read and follow the di-rections on the packaging.
Keep chemicals and other hazardous materials out ofreach of children. Bring leftover or used chemicals toan environmental station for destruction.
Lubrication systemWarm oil can cause burns. Avoid skin contact withwarm oil. Make sure that the lubrication system is notpressurized prior to performing service. Never start oroperate the engine without the oil filler cap in placedue to risk of oil being thrown out.
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Cooling systemAvoid opening the coolant filler cap when the engine iswarm. Steam or hot coolant can squirt out causingburns.
If the filler cap, coolant lines, taps or so on must beopened or removed while the motor is warm the fillercap must be opened slowly and carefully so that pres-sure is released before the cap is completely removedand work is started. Note that the coolant can still behot and cause burns.
Fuel systemAlways protect your hands when searching for leaks.Streaming pressurized liquids can make their way intobody tissues causing serious injuries. There is a riskof blood poisoning.
Always cover the generator if it is placed under thefuel filter. A fuel spill can damage the generator.
Electrical systemDisconnect the power
Before servicing the electrical system the engineshould be stopped and the electrical power switchedoff using the main switch/breakers. External power tothe engine heater, battery charger or other equipmentmounted on the engine must be switched off.
Batteries
Batteries contain a very strong corrosive electrolyte.Protect your eyes, skin and clothing during chargingor other handling of batteries. Always use safetyglasses and gloves.
In case of skin contact, wash with soap and largequantities of water. In case of eye contact rinse im-mediately with large quantities of water and contact adoctor as soon as possible.
Electric weldingRemove the positive and negative cables from thebatteries. Then disconnect all cables connected to thealternator.
Disconnect both connectors from the engine controlmodule.
Always connect the welder earth clamp to the compo-nent to be welded, and as close as possible to theweld site. The clamp must never be connected to theengine or in such a way that current can pass througha bearing.
When welding is completed: Always connect thecables to the alternator and engine control unit con-nector before reconnecting the battery cables.
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IntroductionThis instruction book has been compiled to give you the best possible use of your Volvo Penta industrial engine.It contains the information you need to operate and take care of the engine in a safe and correct manner. Wetherefore ask you to read the instruction book carefully and to learn to handle the engine, controls and additionalequipment in a safe manner before you start the engine.
IMPORTANT! The instruction book describes the engine and equipment that are sold by Volvo Penta. In cer-tain applications there can be variations of for example controls and instrumentation that concern both ap-pearance and function. In these cases we refer you to the instruction book for the application in question.
Environmental careWe all want to live in a pure and healthy environmentwhere we can breathe fresh air, see healthy trees,have clean water in our lakes and oceans and wherewe can enjoy the sunshine without fearing for ourhealth. Unfortunately this is not always the case todaybut it is a situation that we all must work to preserveand protect.
As an engine manufacturer Volvo Penta has a specialresponsibility, therefore care for the environment is acore value in our product development. Today VolvoPenta has a broad engine line where large steps havebeen taken towards reducing exhaust emissions andimproving fuel economy, engine noise and so on.
We hope that you will be careful to preserve thesequalities. Always follow the advice in the instructionbook regarding fuel quality, operation and mainte-nance so that you can avoid unnecessary damage tothe environment. Contact your Volvo Penta dealer ifyou notice changes such as decreased fuel economyor increased exhaust smoke.
Remember to always bring hazardous waste such asdrained oil, coolant, used batteries etc. to an environ-mental station for destruction.
Through our mutual efforts we can make a valuablecontribution to the environment.
Running-inThe engine should be ”run-in” during the first10 hours of operation according to the following:Run the engine as with normal operation. Full-throttleoperation should not occur for more than short peri-ods. Do not run the engine for long periods of time atsteady RPM during the run-in period.
An increase in the consumption of lubricating oil isnormal during the first 100–200 hours of operation. Itis therefore important to check the oil level more oftenthat is normally recommended.
When a clutch is mounted it should be inspected morefrequently during the first days of operation. Adjust-ment may be required to compensate for initial wear ofthe plates.
Fuel and oilsOnly use fuel and oils of a grade matching that recom-mended in the instruction book (see the chapter on”Maintenance” under the fuel and lubricating systemheadings). Other grades can cause problems with op-eration, decreased fuel economy and in the long runeven a shortened lifetime of the engine.
Always change the oil, oil and fuel filters according tothe prescribed intervals.
Maintenance and replacementpartsVolvo Penta engines are constructed for maximal de-pendability and longevity. They are built to survive indemanding environments but also to have the mini-mum possible impact on the environment within whichthey operate. Regular maintenance and use of VolvoPenta original parts will preserve these properties.
Volvo Penta has a worldwide network of authorizeddealers. They are specialists on Volvo Penta productsand have accessories, original parts, test equipmentand the special tools that are necessary for high-quali-ty service and repair work.
Always adhere to the maintenance schedules list-ed in the instruction book and remember to pro-vide the engine/transmission identification num-ber when ordering service and parts.
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Certified enginesFor those of you who own an emissions-certifiedengine that is used in an area where exhaust emis-sions are legally regulated, it is important to rec-ognize the following:
A certification signifies that an engine type has beeninspected and approved by the authorities in question.The manufacturer of the engine guarantees that all en-gines of the same type will match the engine that wascertified.
This places the following special requirementsupon the maintenance and service that you per-form on your engine:
• Maintenance and service intervals recommendedby Volvo Penta must be followed.
• Only Volvo Penta original parts may be used.
• Service on the injector pumps, pump settings andinjectors must always be performed by an autho-rized Volvo Penta repair facility.
• The engine may not be rebuilt or modified with theexception of accessories and service kits devel-oped by Volvo Penta for the engine.
• No changes may be made to the engine’s exhaustor intake air systems.
• No seals may be broken by non-authorized per-sonnel.
In all other cases follow the advice in the instructionbook regarding operation, maintenance and service.
IMPORTANT! In cases of neglected or deficientmaintenance/service as well as use of non-origi-nal parts AB Volvo Penta will no longer be ableto assure that the engine meets conditions ofcertification.Volvo Penta will not settle damages and/or costsassociated with such instances.
WarrantyYour new Volvo Penta industrial engine is covered by a limited warranty according to the conditionsand instructions that are contained in the Warranty and Service book.
Note that AB Volvo Penta’s responsibility is limited to that which is named in the Warranty and Servicebook. Read it carefully immediately following delivery. It contains vital information on subjects such asthe warranty card,services, and maintenance that is your responsibility as the owner to be aware of, check on and per-form. AB Volvo Penta may otherwise completely or partially deny warranty claims.
Contact your Volvo Penta dealer if you do not have a Warranty and Service book as well as acustomer copy of the warranty card.
Introduction
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PresentationTAD1250VE, TAD1251VE and TAD1252VE are in-line, direct-injected, 6-cylinder industrial diesel engines withswitchable internal EGR (Exhaust Gas Recirculation).
They are equipped with electronically controlled fuel management, turbochargers, intercoolers and thermostaticallyregulated cooling systems and electronic RPM regulation.
Technical description
Engine and cylinder block
– Cylinder block and cylinder head of alloyed castiron
– Seven main bearing induction hardened crank-shaft
– Wet replaceable cylinder liners
– Steel pistons
– Three piston rings, the top of which is of the ”key-stone” variety
– Induction hardened overhead camshaft with rollerrocker arms
– Four valves per cylinder
– Replaceable valve seats and valve guides
Fuel system
– Microprocessor-based control unit for fuel delivery(EMS 2)
– Gear-driven feeder pump
– Centrally placed unit injector with electromagneti-cally controlled fuel valves
– Fuel filter of spin-on type and a water separatingfilter
– EMS 2 (Electronic Management System). Seeseparate description
Lubrication system
– Water-cooled oil cooler
– Gear-driven oil pump
– Full flow and bypass oil filters of spin-on type
Intake air compression system
– Turbocharger
Cooling system
– Cooler with expansion tank (option)
– Air-cooled intercooler (option)
Electrical system
– 24V electric system with generator (80A) withcharging sensor
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Presentation
The above plate shows:
(K) Engine family
(J) Swept volume
(A) Engine designation
(F1)Valve clearance, inlet
(F2)Valve clearance, outlet
(I) Emission Control devices
(P) Only constant RPM
(E) Part number – decal
(B) Engine code (in engine family)
(C) Output/RPM
(D) Fuel quantity
(M) Engine speed
(H) Certification approval number (EU)
Explanation of engine designation:
Ex. TAD1250VE
T – Turbo
A – Air-to-air Charge air cooler
D – Diesel engine
12 – Swept volume, liter
5 – Generation
0 – Version
V – Stationary and mobile operation
E – Emissions check
Location of engine plates
The plate above shows:1 Engine designation2 Serial number3 Specification number
Identification numbers
The plate above shows:1 Engine designation2 Specification number3 Serial number engine block
(last six digits)
The plate shows:A Engine designationB Net engine output (without fan)C Max. rpmD Main softwareE Computer kit numberF Product number
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Presentation
1. Expansion tank
2. Alternator
3. Control unit, EMS 2
4. Starter motor
5. Air filter
Orientation
6. Cooling package
7. Oil dipstick
8. Oil filler
9. Fuel filter with fuel pressure sensor
10. Fuel pre-filter with water sensor
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Presentation
1. Coolant level sensor2. Position sensor, camshaft3. Unit injector (one for each cylinder)4. Extra stop5. Charge pressure and temperature sensor6. Main relay7. Fuel pressure sensor8. Coolant temperature sensor9. Starter motor10. Starter motor relay
11. Position sensor, flywheel12. Connector for diagnostic tool, 6-pin13. 8-pin connector engine interface14. Water in fuel, fuel filter15. Control unit16. OiI temperature and level sensor17. Crankcase pressure18. Oil pressure sensor19. Main fuse 10 A20. Alternator
Location of sensors
64 51 2
16 14 13
3
15
7
12
8
11
9
10
1718
19
20
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Presentation
21. Air filter indicator22. Piston cooling pressure
21
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Presentation
EMS 2EMS 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 and includes fuel control and diagnostic func-tion.
Fuel control
The engine fuel requirement is analyzed up to 100times per second. The amount of fuel injected into theengine and the injection advance are fully electronical-ly controlled, via fuel valves and the unit injectors.
This means that the engine always receives the cor-rect volume of fuel in all operating conditions, whichoffers lower fuel consumption, minimal exhaust emis-sions etc.
Diagnostic function
The task of the diagnostic function is to discover andlocalize any malfunctions in the EMS 2 system, toprotect the engine and to ensure operation in the eventof serious malfunction.
If a malfunction is discovered, this is announced bywarning lamps, a flashing diagnostic lamp or in plainlanguage on the instrument panel, depending on theequipment used. If a fault code is obtained as a flash-ing code or in plain language, this is used for guidancein any fault tracing. Fault codes can also be read byVolvo’s VODIA tool at authorized Volvo Penta work-shops.
If there is a serious malfunction, the engine will beshut down altogether, or the control unit will reduce thepower delivered (depending on application). Onceagain, a fault code is set for guidance in any fault trac-ing.
Summary
The system includes sensors, control unit and unit in-jectors. The sensors send input signals to the controlunit, which controls the unit injectors in its turn.
Information from the sensors provides exact informa-tion about current operation conditions and allows theprocessor in the control unit to calculate the correctfuel injection volume and timing, check engine statusetc.
Input signals
The control unit receives input signals about engineoperating conditions etc. from the following compo-nents:
– coolant temperature sensor
– charge pressure / charge temperature sensor
– crankcase pressure sensor
– position sensor, camshaft
– speed sensor, flywheel
– piston cooling pressure sensor
– coolant level sensor
– oil pressure sensor
– oil level and oil temperature sensor
– fuel pressure sensor
– water in fuel indicator
– air filter indicator.
Output signals
The control unit controls the following components onthe basis of the input signals received:
– unit injectors
– starter motor
– main relay
– preheating relay
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Presentation
Instrument, EMS 2NOTE! All instruments are accessories.
CIU - Control Interface UnitThe CIU is the “translator” between the EMS 2 controlunit and the customer’s own control panel. The CIUhas two serial communication links, a fast one and aslow one.
The fast one is a so-called CAN link. All data relatedto instruments, indication lamps, connectors and po-tentiometers is controlled by this link.
The slow link manages diagnostic information forflashing codes etc.
DU - Display UnitThe DU is an instrument panel which shows engineworking values graphically on an LCD screen. It con-sists of an computerised unit for permanent installa-tion in a control panel.
The DU is connected between the engine control unitand the CIU or DCU.
Easy Link instrument(only together with a CIU)The following “Easy Link” instruments are available:– Engine speed / hours counter (fault codes are also
displayed on the tachometer display when the di-agnostic button is pressed)
– Coolant temperature
– Oil pressure
– Oil temperature
– Battery voltage
– Alarm panel
– Charge pressure
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Presentation
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 theengine control unit. DCU has several functions, such as: engine control, monitoring, diagnostics and parametersetting.
The menus in the DCU system can be used to check, and in some cases to set a number of different functions inthe EMS system.
NOTE! The menus and illustrations shown here are the English version. The language can be changed, however.Please refer to the “Setup” menu.
1. LED display
2. START. Starts the engine
3. SPEED -. Reduces engine speed
4. SPEED +. Increases engine speed
5. STOP. Stops the engine
6. ON/OFF. Starts and stops the system
7. Scroll downwards in menus
8. SEL. Selects in menus
9. Scroll upwards in menus
10. ESC. Return to previous menu selection
StartWhen the DCU panel is started up, the “Engine Data” menu is displayed. Press “ESC” to come to the main menu.
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Presentation
MenusThere are several sub-menus under each main menu.There is not space for all the menu choices on thedisplay. To scroll through the menus, use the “7” and“9” buttons on the display. Press the “SEL” button, no.“8” to make a selection. Please refer to the illustrationon the previous page.
NOTE! The “Setup” menu can be used to select thelanguage that you want to use on the display.
Main menu� Engine data, relevant engine data.
� Preheat, manual activation of pre-heating
� Governor mode, activation of droop.
� Diagnostics, shows fault codes in plain language.
� Trip reset, resets trip data
� Setup, parameter setting
� Information, shows the data for the applicablehardware, software, data set and engine identifica-tion of the engine and DCU
Engine datashows relevant engine data.
• Engine speed, can be controlled with the “SPEED +”and “SPEED –” buttons (rpm)
• Charge pressure (kPa)
• 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)
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Presentation
Preheatmanual activation of pre-heating. When it is activated,the EMS system senses when started if pre-heating isneeded. For automatic pre-heating, please refer to the“Setup” / “Pre-heat on ignition” menu.
The pre-heating time is adjusted to suit the enginetemperature, and can last for up to 50 seconds bothbefore and after starting. Also refer to “Starting proce-dure, EMS 2”.
• Press “SEL”, the text “Preheat requested” is dis-played.
• The display automatically returns to the “EngineData” menu.
Governor modeactivates/shuts off droop. To set the droop level,please refer to the “Setup” / “Governor gradient” or“Governor droop” menus.
• Select “Isochronous mode” or “Droop mode” withthe SEL button.
Diagnosticsshows the error list containing the 10 latest active andinactive faults. The fault code are shown as text onthe display.
• Scroll through the error list with the arrow keys.
Trip resetresets trip data, such as fuel consumption.
• Press the SEL button to reset trip data.
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Presentation
Setupparameter 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 ismade with the SEL button) are:
• Set application, setting of “Versatile” or “Genset”.Different menus appear under “Customer param-eter”, depending on what is chosen here.
• Unit, selection of units of measurement (metric orUS units)
• Language, selection of the language shown in thedisplay. You can choose between English,French, German and Spanish.
• Stop energized to, setting for the external stopinput. Activated at “Stop” or “Run”.“Stop”: The stop input must be connected tovoltage to stop the engine.“Run”: The stop input must be connected to volt-age to run the engine.
• Customer parameter, alarm limit setting. Pleaserefer to “Customer parameter / Versatile” and“Customer parameter / Genset”.
• Throttle input setting, setting of speed controland voltage limits. See “Throttle input setting”.
• Display setting, display setting. See “Display set-ting”.
Customer parameter / Versatile• Idle engine speed - setting idling speed.
• Preheat on ignition - activation of automatic pre-heating. The engine control system senses if pre-heating is needed and activates it directly whenswitched on.
• Governor gradient (Nm/rpm) - setting the drooplevel, when this has been activated. Please referto “Governor droop” in the main menu for activa-tion.
• Oil temp warning limit (°C) - setting the alarmlimit for the oil temperature.
• Coolant temp warning limit (°C) - setting thealarm limit for the coolant temperature.
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Presentation
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 whenswitched on.
• Governor droop (%) - setting the droop level,when this has been activated. Please refer to“Governor droop” in the main menu for activation.
• Overspeed limit (%) - setting the speed for theexcess speed alarm, % of set engine speed.
• Overspeed shutdown - activation of engine shutdown when the excess speed alarm is activated.Please refer to “Overspeed limit” to activate thealarm limit for the excess speed alarm.
• Oil temp warning limit (°C) - setting the alarmlimit for the oil temperature.
• Coolant temp limit (°C) - setting the alarm limitfor the coolant temperature.
Throttle input settingspeed control setting (throttle operation).
• Set throttle mode-“OFF” - engine speed is controlled via the DCUpanel.“ext throttle input” - engine speed is controlledwith a potentiometer (accelerator).“ext voltage input” - engine speed is controlled byan external unit.
• Set idle voltage (V) - setting the voltage level atidle.
• Set max voltage (V) - setting the voltage level atmaximum speed.
0
100
Idling MaxVoltage (V)
Potentiometervalue (%)
0
100
Max IdlingVoltage (V)
Potentiometervalue (%)
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Presentation
Display settingsettings for the display. Adjustment is done with the“7” and “9” buttons, please refer to the DCU panel inthe illustration.
• Set contrast (%) - display contrast adjustment.
• Set backlight time (sec) - sets the time (in sec-onds) for background illumination in the display.The light is then switched off if the panel is notused.
• Set backlight brightness - adjustment of illumi-nation strength in the display.
Informationshows the data for the engine and DCU.
• Engine hardware ID - part number of the enginecontrol module
• Engine software ID - part number of the softwarein the engine control module
• Engine dataset1 ID - part number of engine dataset 1.
• Engine dataset2 ID - part number of engine dataset 2.
• Vehicle ID - chassis number
• DCU hardware ID - part number of the DCU.
• DCU software ID - part number of the software inthe DCU.
• DCU dataset1 ID - part number of DCU data set 1.
• DCU dataset2 ID - part number of DCU data set 2.
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Starting the engineMake a habit of always visually checking the engine and engine compartment prior to starting the engine. This willhelp you to quickly notice if any abnormal conditions have occurred or are occurring. Check also to verify that theinstruments show normal values after start-up.
Before starting
• Check that the oil level is between the MIN andMAX marks on the oil dipstick (1). See the chap-ter ”Maintenance, lubrication system”.
• Open the fuel cocks.
• Make sure that there is no leakage of coolant, fuelor oil.
• Check the air filter’s pressure drop indicator (op-tion). See the chapter ”Maintenance, Engine, gen-eral”.
1
• Check the coolant levels and that the radiator isnot blocked on the outside. See the chapter”Maintenance, cooling system”.
WARNING! Do not open the coolant filler cap (1)when the engine is warm. Steam or hot coolantcan squirt outDo not open the pressure cap (2).
• Turn on the main switches.
IMPORTANT! Never switch off the power withthe main switch while the engine is running. Thegenerator can be damaged.
• Set the throttle to idle and disengage the clutch/put the transmission in neutral.
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Starting method EMS 2The pre-heating time is adjusted to suit the enginetemperature, and can last for up to 50 seconds bothbefore and after starting.
The starter motor connection time is maximized to 30seconds. After that, the starter motor circuit is cut for80 seconds to protect the starter motor against over-heating.
NOTE! Preheating must be activated at temperatturesbelow 0°.
With pre-heating
1. Press the “ON/OFF” button (6).
2. Press the “SEL” button (7) to come to the mainmenu.
3. Scroll down to Preheat with button (9). Press the“SEL” button (7).
4. In the pre-heat menu, press the “SEL” button (7)to select pre-heating. The text “Preheat activeplease wait” is shown in the display.
5. Wait until the text has gone out and then pressthe “START” button (2).
Without pre-heating
1. Press the “ON/OFF” button (6).
2. Press the “START” button (2).
Leave the engine to idle for the first 10 seconds. Thenwarm the engine up at low speed and under low load.
IMPORTANT! Never race the engine when it iscold.
2
6
7
9
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Volvo Penta start lockNOTE! Preheating is option.
1. Turn the key to the ”I” position and check the indi-cator lamps.
2. Position ”II”. Preheating is activated. Wait until thepreheating indicator lamp goes out. Preheatingtime is dependent upon engine temperature.
3. Start the engine with position “III”. Let the key re-turn to position ”I” immediately once the enginehas started.
NOTE! The engine has a built-in starter motor inter-lock to prevent inadvertent activation of the startermotor while the engine is running. The key must beturned to the “O” position before attempting to startagain.
Let the engine run at 500–700 rpm for the first 10 sec-onds. Following this, warm up the engine using lowrpm and low loading.
IMPORTANT! Never rev-up the engine when it iscold.
Alternative preheating:
1. Turn the key to the ”I” position and check the indi-cator lamps. Preheating activates automatically.Preheating time is dependent upon engine tem-perature.
2. Start the engine with position ”III”. Let the key re-turn to position ”I” immediately once the enginehas started.
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Start-up under extreme coldTo facilitate and in certain cases allow start-up underextremely cold conditions certain procedures must befollowed:
Use a winter fuel (from a well-known supplier) that hasbeen approved for the temperature in question. Thisminimizes the risk of wax precipitation in the fuel sys-tem. During extremely low temperatures use of a fuelheater is recommended.
In order to insure sufficient lubrication we recommenduse of synthetic oil of the recommended viscosity forthe temperature in question (see chapter ”Mainte-nance, lubrication system). Synthetic oils retain theirlubricating properties over a wider range of tempera-tures than mineral oils.
Preheat the coolant by using a separately mountedelectric engine heater. In extreme cases it can benecessary to use a diesel-powered engine heater.Consult your Volvo Penta dealer.
IMPORTANT! Make sure that the cooling sys-tem is filled with a glycol mixture. See the chap-ter ”Maintenance, cooling system”.
The batteries must be in good condition. Cold reducesthe capacity of the batteries. Increasing the total bat-tery capacity may be necessary.
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Start with booster batteries
WARNING! Batteries (especially booster batter-ies) contain oxyhydrogen gas that is very explo-sive. A spark, which can occur if the booster bat-teries are improperly connected, can be suffi-cient to cause a battery to explode causing dam-age and/or injury.
1. Make sure that the booster batteries are con-nected (in series or in parallel) so that the groundvoltage corresponds to the engine’s system volt-age.
2. First connect the red booster cable (+) to thebooster battery and then to the dead battery. Thenconnect the black booster cable (-) to the boosterbattery, then to a place that is a distance awayfrom the dead battery, e.g. next to the mainswitch on the negative wiring or at the negativecable’s connection to the starter motor.
3. Start the engine.
WARNING! Do not disturb the connections whileattempting to start the engine (risk for creatingsparks) and do not lean over any of the batteries.
4. Remove the cables in reverse order.
WARNING! The normal cables to the standardbatteries must absolutely not be modified.
Never use starting spray
WARNING! Never use starting spray or othersimilar substances to help start an engine. Thiscould cause an explosion in the intake tract. Thisposes a risk of injury.
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OperationCorrect operation technique is very important for both fuel economy and engine life. Always let the engine warmup to normal operating temperature before operating at full power. Avoid sudden throttle openings and operation athigh engine speeds.
Checking instrumentsCheck all instruments directly after starting, and thenregularly during operation.
IMPORTANT! On engines which operate continu-ously, the lubrication oil level must be checked,at least every 24 hours. Please refer to the“Maintenance, lubrication system” chapter.
Fault indicationIf the EMS 2 system receives abnormal signals fromthe engine, the control unit generates fault codes andalarms, in the form of lamps and audible warnings.This is done by means of CAN signals to the instru-ment.
More information about fault codes and fault tracing isfound in the “Diagnostic function” chapter.
Operation at low loadAvoid long-term operation at idle or at low load, sincethis can lead to increased oil consumption and even-tually to oil leakage from the exhaust manifold, sinceoil will seep past the turbocharger seals and accompa-ny the induction air into the inlet manifold at low turboboost pressure.
One consequence of this is that carbon builds up onvalves, piston crowns, exhaust ports and the exhaustturbine.
At low load, the combustion temperature is so low thatfull combustion of the fuel can not be ensured, whichmeans that the lubrication oil can be diluted by dieselfuel, and the exhaust manifold will eventually leak oil.
If the following points are done as a complementto normal maintenance, there will be no risk ofmalfunctions caused by operation at low load.:
• Reduce operation at low load to a minimum. If theengine is regularly test run without load once aweek, operation duration should be limited to 5minutes.
• Run the engine at full load for about 4 hours oncea year. Carbon deposits in the engine and exhaustpipe can then be burned off.
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Stopping the engineIn case of extended time between uses the engine should be run until warm at least once every 14 days. This pre-vents corrosion of the engine. If the engine will not be used for more than two months preservation should be per-formed. See the chapter ”Storage”.
IMPORTANT! In case of freezing temperatures liquid in the cooling system must have sufficient antifreeze.See the chapter ”Maintenance, cooling system”. A poorly charged battery can freeze and break.
Before shutdownAllow the engine to run a few minutes with no load be-fore it is shut down. This permits an evening out oftemperatures within the engine, which prevents ”after-boiling” as well as cooling the turbocharger somewhat.This contributes to a lengthened useful life withoutdisruptions.
Stop
• Disengage the clutch (if possible).
• Depress the “STOP” button / turn the key to "S".
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Extra stopThe extra stop (AUX STOP) is located on the left sideof the engine, above the control unit.
WARNING! Approaching or working on a runningengine is a safety risk. Beware of rotating partsand hot surfaces.
After shutdown
• Check the engine with respect to possible leak-age.
• Switch off the main switch during extended peri-ods without use.
Stopping the engine
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Maintenance schedule
MAINTENANCE SCHEDULE
WARNING! Prior to starting maintenance work the chapter ”Maintenance” should beread carefully. In it you will find instructions for how the work can be carried out in asafe and correct manner
IMPORTANT! When both operational and calendar times are given maintenance shouldbe performed in accordance with the first interval to arrive. Maintenance points markedwith should be performed by an authorized Volvo Penta service facility.
Daily, before the first start-up
• Engine and engine compartment, general inspection ......................................page 31
• Air filter indicator, check 1) .............................................................................page 33
• Oil level, check and add .................................................................................page 35
• Coolant level, check level ..............................................................................page 391) Change the air filter at least every 12th month.
Every 50th operational hour / at least every 12th month
• Fuel filter. Drain water/impurities ....................................................................page 45
After the first 150 operational hours
• Engine oil, change 1) ......................................................................................page 351) The oil change is recommended, the new engine oil should be one that is recommended
by Volvo Penta. NOTE! Oil filter must be changed with every oil change.
Every 50–600 operational hours / at least every 12th month
• Engine oil, change 1), 2) ....................................................................................page 35
• Oil filter/Bypass filter, change 2) .....................................................................page 361) Oil change intervals will vary depending upon the grade of the oil and the amount of sulfur in the fuel.2) NOTE! Oil filter must be changed with every oil change.
Every 400th operational hour / at least every 12th month
• Fuel tank (sludge collector), drain. ............................................................. not shown
• Alternator belt, check/adjust ..........................................................................page 32
• Batteries, check electrolyte level ...................................................................page 47
GeneralYour Volvo Penta engine and its equipment are built to provide a high degree of reliability and a long useful life.They are built to have the minimum possible effect upon the environment. Preventative maintenance according tothe maintenance schedule and use of original Volvo Penta parts will preserve these qualities and help to avoid un-necessary operational disturbances.
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Every 800th operational hour / at least every 12th month
• Charge air pipes, check for leaks ...................................................................page 31
• Fuel pre-filter, change ....................................................................................page 44
• Fuel filter, change ..........................................................................................page 45
• Fuel pre-filter. Check .................................................................................. not shown
Every 1000 operational hours / at least every 6th month
• Coolant filter, change 1) ..................................................................................page 421) Not concurrent with the change of coolant.
Every 2000 operational hours
Turbocharger, check .................................................................................. not shown
Valve play/Double rocker (IEGR), check/adjust ......................................... not shown
Every 12th month
EDC system. Check with diagnosis tool .................................................... not shown
Engine, general check ................................................................................ not shown
• Air filter element, change ........................................................................... not shown
• Engine, cleaning/painting ........................................................................... not shown
• Air Filter, tank ventilation, change. ............................................................. not shown
• Air filter, air compressor, change. .............................................................. not shown
Every 48th month or every 10,000 operational hours
Cooling system, check/cleaning .....................................................................page 41
Coolant, change ........................................................................................ page 39-40
Newly rebuilt engine:
After the first 250 hours of operation
Valve play, adjust ...................................................................................... not shown
Maintenance schedule
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Maintenance
Engine, general
This chapter contains general technical information and instructions detailing how the recommended maintenanceshould be performed. Read carefully through the instructions before starting the task. The time frames for wheneach maintenance point should be performed are given in the previous chapter: Maintenance schedule.
WARNING! Read through the safety instructions for maintenance and service work in the chapter: Safety in-formation, before starting to work.
WARNING! Maintenance and service work shall be performed on a stopped engine if not otherwise indicated.Stop the engine before the engine cover/hood is opened or removed. Make inadvertent start-up impossibleby removing the starting key and disconnect the power using the main switch.
General inspectionGet in the habit of giving the engine and engine com-partment a visual inspection before starting the en-gine and after operation when the engine hasstopped. This will help you to quickly realize if some-thing unusual has happened or is happening.
Look especially carefully for oil, fuel and coolant leak-age, loose screws, worn or loose drive belts, looseconnections or damaged hoses and wires. The in-spection only takes a few minutes but can mean thatserious service interruptions and costly repairs can beavoided.
WARNING! Puddles of fuel, oil or grease on theengine or in the engine compartment are a firehazard and must be removed as soon as theyare noticed.
IMPORTANT! If leakage of oil, fuel or coolant isdetected the cause must be determined and theproblem resolved before the engine is started.
IMPORTANT! When cleaning with a high-pres-sure sprayer the following instructions must bekept in mind: Never point the spray at seals, rub-ber hoses or electric components.
Charge air pipes, checkCheck the condition of the charge air pipes andclamps looking for leaks or other damage.
Change as needed. Tighten the clamp with the torquethat is stated on the clamps.
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Maintenance
32
Alternator belt, change
IMPORTANT! Always change a drive belt whichappears worn or cracked.
1. Disconnect the main switch(es) and check thatthe engine is not connected to system voltage.
2. Remove the fan guard and fan ring round the cool-ing fan.
3. Remove the belt guard.
4. Insert a 1/2” square wrench in the belt tensioner.Turn the tensioner away with the wrench and liftthe alternator belt off.
5. Check that the pulleys are clean and undamaged.
6. Turn the tensioner away with the 1/2” wrench andinstall the new alternator drive belt.
7. Install the belt guards.
8. Install the fan guard and fan ring round the coolingfan.
9. Start the engine and do a function check.
Alternator drive belt, check/adjust.Inspection should be done after operation, when thebelt is hot.
The alternator belt have an automatic belt tensionerand do not need to be adjusted.
Check the condition of the drive belt. It should be pos-sible to press the alternator belt down about 3-4 mm(0,118-0,157 ") between the pulleys.
Change as necessary, please refer to “Alternator belt,change”.
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Maintenance
33
Air filter Check/change. (Option)The engine is equipped with electronic air filter indica-tion. A pressure drop in the air filter provides an outputsignal which is announced as a warning on the instru-ment panel. The air filter then needs to be checkedand possibly changed.
NOTE! Scrap the old filter. No cleaning or reuse ispermissible.
IMPORTANT! In continuous operation, the filtershould be checked every 8 hours.
Driving in extremely contaminated environmentssuch as coal mines or rock crushers requiresspecial air filters.
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Maintenance
34
Lubrication system
ViscosityViscosity should be chosen using the adjoining table.Note! The temperature values refer to steady outsideair temperature.
* Refers to synthetic or partially synthetic oil
Oil change amountSee chapter ”Technical Data”.
Oil change intervals can vary between 50–600 hours depending upon the grade of the oil and the sulfur content ofthe fuel. Note that the oil change intervals may never exceed a period of 12 months.
If change intervals longer than those provided are desired, the condition of the oil must be checked by the manu-facturer of the oil by regular testing.
NOTE! Oil filter must be changed with every oil change.
Sulfur content in fuel, by weight
< 0.3 % 0.3 – 0.5 % > 0.5 %1)
Oil grade Oil change interval: Reached first in operation
VDS-3 600 hours / 12 month 300 hours / 12 month 150 hours / 12 month
VDS-2 and ACEA E7 2) 400 hours / 12 month 200 hours / 12 month 100 hours / 12 monthVDS-2 and ACEA E5 2)
VDS-2 and Global DHD-1 2)
VDS-2 and API CI-4 2)
VDS-2 and API CH-4 2)
VDS and ACEA E3 2) 200 hours / 12 month 100 hours / 12 month 50 hours / 12 monthACEA: E7, E5, E4API: CI-4, CH-4, CG-4
1) If sulfur content is > 1.0% by weight, use oil with TBN > 15.2) The engine oil must comply with both quality requirements.
NOTE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the qualityrequirements above.
VDS = Volvo Drain SpecificationACEA = Association des Constructeurs Européenne d’AutomobilesGlobal DHD = Global Diesel Heavy DutyAPI = American Petroleum InstituteTBN = Total Base Number
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Oil level, check and addThe oil level should be within the marked area on thedipstick (1) and should be checked daily before thefirst start.
Add oil using the filler opening (2) on the side of theengine.
Check that the correct level is reached. Wait a fewminutes so that the oil has time to run down into theoil pan.
IMPORTANT! Do not fill over the maximum oillevel. Only use oil of the recommended grade(see previous page).
Engine oil, change
WARNING! Hot oil can cause severe burns.
NOTE! Oil should be changed while the engine iswarm.
1. Connect the drain hose to the oil bilge pump andmake sure that leakage can not occur.
2. Pump out the oil (or remove the drain plug anddrain the oil).
NOTE! Collect all the used oil and deliver it to a usedoil collection facility.
3. Remove the drain hose (or replace the drain plug).
4 . Fill with new oil.
21
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Maintenance
36
Oil filter / Bypass filter, change
WARNING! Hot oil can cause severe burns.
1. Clean the oil filter housing.
2. Remove all oil filters using appropriate filterwrenches (1).
3. Clean the sealing surface on the filter housing,making sure that no gasket residue remains.
4. Spread a thin layer of engine oil on the new filter’ssealing rings.
5. Install the new oil filter. The two full-flow filtersshould be tightened 1/2 to 3/4 turn following sealcontact. The bypass filter should be tightened 3/4to 1 turn following seal contact.
6. Fill with oil, start the engine and operate it for20-30 seconds.
7. Shut off the engine, check the oil level and fillwith oil as needed.
8. Check the seals around the oil filters.
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Maintenance
37
Cooling system
The cooling system ensures that the engine operates at the correct temperature. It is a closed circuit system andmust always be filled with a mixture of at least 40 % concentrated coolant and 60 % water to protect against inter-nal corrosion, cavitation and damage caused by freezing.
We recommend that you use “Volvo Penta Coolant, Ready Mixed”, alternatively “Volvo Penta Coolant” (con-centrated) mixed with pure water according to spec, see “Coolant. Mixture”. Only coolant of this quality is suitedtoo and approved by Volvo Penta.
The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency for an adequateprotection of the engine. Using anticorrosion additive exclusively is not permitted in Volvo Penta’s engines. Neveruse water by itself as coolant.
IMPORTANT! Coolant, with a suitable consistency, must be used all year round. This applies even if there isnever 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 hasbeen used or if the instructions concerning coolant mixing have not been followed.
NOTE! The anticorrosive agents become less effective after a time, which means that the coolant must be re-placed, see “Maintenance schedule”. The cooling system should be flushed out at the same time as the coolant isreplaced, see “Cooling system. Cleaning”.
“Volvo Penta Coolant” is a concentrated coolantthat is to be mixed with water. It has been developedto function optimally with Volvo Penta’s engines andprovides excellent protection against corrosion, cavi-tation and frost damage.
“Volvo Penta Coolant, Ready Mixed” is a ready-mixed coolant, 40% “Volvo Penta Coolant” and 60%water. This concentration protects the engine againstcorrosion, cavitation damage and freezing conditionsdown to -28 °C (18°F).
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Maintenance
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Coolant. MixtureWARNING! All glycol is hazardous and harmfulto the environment. Do not consume!Glycol is flammable.
IMPORTANT! Ethylene glycol must not bemixed with other types of glycol.
Mix: 40 % “Volvo Penta Coolant” (conc. coolant) 60 % water
This mixture protects the engine against internal cor-rosion, cavitation and frost damage down to -28°C(-18°F). (Using 60 % glycol lowers the freezing pointto -54 °C (65°F)). Never mix more than 60 % concen-trate (Volvo Penta Coolant) in the cooling liquid, thiswill give reduced cooling effect and increase the riskof overheating, and will give reduced freezing protec-tion.
IMPORTANT! Coolant must be mixed with purewater, use distilled - deionized water. The wa-ter must fulfill the requirements specified by Vol-vo Penta, see “Water quality”.
IMPORTANT! It is extremely important that thecorrect concentration of coolant is added to thesystem. Mix in a separate, clean vessel beforeadding into the cooling system. Ensure that theliquids mix properly.
Water quality
ASTM D4985:
Total solid particles ...................................... < 340 ppm
Total hardness: ............................................ < 9.5° dH
Chloride ......................................................... < 40 ppm
Sulfate ........................................................... < 100 ppm
pH value ........................................................ 5,5–9
Silica (acc. ASTM D859) .............................. < 20 mg SiO2/l
Iron (acc. ASTM D1068) .............................. < 0.10 ppm
Manganese (acc. ASTM D858) ................... < 0.05 ppm
Conductivity (acc. ASTM D1125) ................ < 500 µS/cm
Organic content, CODMn (acc. ISO8467) .... < 15 mg KMnO4/l
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Coolant level, check
WARNING! Do not open the coolant filler cap (1)when the engine is warm. Steam or hot coolantcan squirt out as pressure is released.
NOTE! Only open the filler cap (1). Do not open thepressure cap.
The coolant level should be above the MIN mark. Addcoolant as needed according to the description in”Adding, cooling system”.
Adding, cooling system
WARNING! Do not open the coolant filler cap (1)when the engine is warm. Steam or hot coolantcan squirt out as pressure is released.
NOTE! Do not open the pressure cap.
1. Open the filler cap (1).
NOTE! Use only Volvo Penta recommended coolantand mixtures.
2. Mix the correct amount of coolant ahead of time(see the table below) so that it can be assuredthat the system has been filled.Filling must not be done so quickly that air pock-ets form in the system. Air must be given thechance to flow out through the filler opening anddrain valves.
When adding coolant, the coolant level should bebetween the MIN and MAX markings.
3. Start the engine when the cooling system hasbeen bled of air and filled completely. If there is aheater attached to the engine’s cooling systemthe heater control valve should be opened and theunit should also be bled of air during filling.
4. Stop the engine after approximately 1 hour, checkthe coolant level and add coolant as needed.
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Draining, cooling system
WARNING! Do not open the coolant filler cap (1)when the engine is warm. Steam or hot coolantcan squirt out.
1. Remove the filler cap (1).
2. Open all of the drain valves. Drain the coolantfrom the radiator. Use drain hose that can be or-dered from Volvo Penta, the drain cock (P) is lo-cated under the radiator.
3. Make sure that all coolant runs out. Deposits mayexist just inside of the cocks/plugs that must becleaned away. If this is not done there is a riskthat coolant will be left in the engine where it cancause serious damage.Check to see if the installation has additionalcocks or plugs at the lowest points of the coolantsystem.
4. Close the cocks and replace any plugs.
P = Coolant drain cock/plug
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Maintenance
41
Cooling system, cleaning
IMPORTANT! Cleaning must not be done ifthere is a risk of freezing in the cooling system,since the cleaning solution does not have anyfrost protection properties.
NOTE! If the cooling system is flushed regularly, forexample by draining and refilling with rust-preventativefluid, a smaller amount of flushing additive or simplerinsing with clean water can be sufficient.
1. Drain the cooling system, see “Draining, coolingsystem”.
2. Rinse the cooling system clean with water.
3. Fill the cooling system with radiator flushingagent, follow the instructions on the package.
4. Run the engine until normal operating temperaturehas been reached and then for another 2 hours.
NOTE! As an alternative the cooling system can befilled with 15–20% concentrated coolant which isdrained after 1–2 days of operation.
5. Carefully flush the system at once with hot waterto prevent any dirt from settling back on the inte-rior surfaces, and to remove any traces of acid.Make sure that any heater controls are set to fullheat during emptying.
NOTE! To prevent dissolved dirt etc. from settling inthe cooling system the emptying must be done quick-ly, within 10 minutes, without leaving the engine sta-tionary for a long time before emptying. Remove thefiller cap and the lower radiator hose, if fitted, to in-crease the rate of emptying.
6. Fill the system with Volvo Penta neutralizing mix-ture, follow the instructions on the package.Neutralize the residual cleaner for 10-15 minutesat normal working temperature.
7. Carefully flush the system at once with hot water.
8. When the cooling system is completely clean, fillit with new coolant that is recommended by VolvoPenta.
IMPORTANT! It is extremely important that thecorrect concentration of coolant is added to thesystem. Mix in a separate, clean vessel beforeadding into the cooling system. Ensure that theliquids mix properly.
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Maintenance
42
Coolant filter, change1. Turn the valve (1) 90° to stop the flow through the
coolant filter.
2. Remove the coolant filter using an appropriate fil-ter wrench. Make sure that no residue from the oldgasket remains on the housing.
3. Spread a thin layer of engine oil on the new cool-ant filter’s gasket. Tighten the coolant filter byhand until the rubber seal contacts the sealingsurface on the filter bracket. Tighten the coolantfilter 1/2 turn.
4. Turn the valve (1) 90° to start the flow through thecoolant filter again.
5. Start the engine and check for leaks.
6. Shut-off the engine and check the coolant level,see ”Coolant level, check”.
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Maintenance
43
Fuel system
Fuel specificationThe fuel must at least satisfy national and interna-tional standards for market fuel, for example:
EN 590 (with nationally adjusted environmental andtemperaturerequirements)
ASTM-D975-No. 1-D, 2-D
JIS KK 2204
Sulfur content: According to legal requirements ineach respective country. If the sulfur content ex-ceeds 0.5 percent by weight oil change intervalsmust be changed, see “Lubrication system”.
Note that low-density fuel (urban diesel in Swedenand citydiesel in Finland) can cause a power reduc-tion of approximately 5% and a decrease in fueleconomy of approximately 2–3%.
Only use fuel of the recommended grade according to the fuel specification below. Always make sure to maintaina high level of cleanliness when fueling and when working with the fuel system.
All work involving the engine’s unit injectors must be performed by an authorized service location.
WARNING! Risk of fire. Work on the fuel system must be performed on a cold engine. Fuel leakage andspillage onto hot surfaces or electrical components can cause a fire. Store fuel-soaked rags in a fire-safemanner.
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Fuel filter, change
NOTE!Do not fill the new fuel filter with fuel before as-sembly. There is a risk that contamination could getinto the system and cause malfunctions or damage.
WARNING! The fuel filter must be changed whenthe engine is cold, to avoid the risk of fire due tospilled fuel on hot surfaces.
1. Clean round the fuel filter.
2. Remove the filter with a suitable filter remover.Collect any spilled fuel in a collection vessel.
3. Clean the filter mating surface on the filterbracket.
4. Lubricate the seal with diesel fuel and install thenew fuel filter. Tighten the fuel filter in accordancewith the instructions on the fuel filter.
5. If necessary, vent the fuel system, please refer to“Fuel System, Venting”.
NOTE! If a water trap is installed: change the filter init at the same time as the fuel filter, and clean the wa-ter trap in the plastic bowl under the filter with a softrag.
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Fuel pre-filter, change1. Undo the cable from the water trap sensor.
2. Remove the water trap filter from the filter bracket.Collect any spilled fuel in a collection vessel.
3. Remove the lower part of the water trap from thefilter.
4. Clean the lower part of the water trap with a softrag. Check that the drain hole in the lower part isnot blocked.
5. Install a new seal on the lower part and lubricatethe seal with diesel fuel. Reinstall the lower part ofthe filter.
6. Lubricate the seal with diesel fuel. Screw the filteronto the filter bracket by hand until the rubber sealjust touches the mating surface. Then tighten afurther half turn, no more.
7. Connect the cable to the water trap sensor.
8. If necessary, vent the fuel system, please refer to“Fuel System, Venting”.
Draining condensate, fuel system
NOTE!Put a collection vessel under the fuel filter tocollect the condensate and fuel.
1. Open the drain nipple (1) in the base of the pri-mary fuel filter.
2. Tighten the drain tap (1) when fuel without waterstarts to run out.
Venting the fuel systemThe system does not need to be vented unless it hasbeen run completely dry. Venting is then done with thehand pump on the fuel filter bracket.
1
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Electrical system
The engine is equipped with a 2-pole electric system and with an alternator. System voltage is 24V.
WARNING! Before performing service on the electric system the engine should be stopped and the powerdisconnected at the main switch. All connections to battery chargers or other equipment must be discon-nected.
Main switchThe main switch must never be switched off beforethe engine has been stopped. If the circuit betweenthe generator and the battery is broken while the en-gine is running the generator and the electronics canbe damaged. For the same reason reconnecting of thecharging circuits must never be carried out while theengine is running.
IMPORTANT! Never switch off the power withthe main switch while the engine is running.
FusesThe engine is equipped with a 10A fuse that shuts offthe power in case of an overload in the electrical sys-tem.
The fuse is placed adjacent to the engine control uniton the engine’s left side.
Note! The engine will stop if the fuse blows out.
If the fuse blows out often an authorized Volvo Pentarepair facility should be contacted to investigate thecause of the overload.
Electrical connectionsCheck that electrical connections are dry, free fromoxide and that they are securely tightened. Spraythese connections as necessary with water-repellentspray (Volvo Penta universal oil).
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Batteries, maintenance
WARNING! Fire and explosion risk. Batteriesmay never be exposed to open flame or sparks.
WARNING! Never confuse the plus and minuspoles of the batteries. Risk of causing sparksand explosion.
WARNING! Battery electrolytes is strongly corro-sive. Protect eyes, skin and clothing during allhandling of batteries.
WARNING! Always use safety glasses andgloves. In case of skin contact, wash with soapand large quantities of water.
WARNING! In case of eye contact rinse immedi-ately with large quantities of water and contact adoctor as soon as possible.
Connection and disconnection
When connecting batteries first connect the + cable(red) to the battery’s + pole. Then connect the – cable(black) to the battery’s – pole.
When disconnecting batteries disconnect the – cable(black) first, then the + cable (red).
Cleaning
Keep the batteries dry and clean. Contamination andoxidation on the battery and the battery poles cancause current leaks, a reduction in voltage and dis-charge, especially during times of humid weather.Clean oxidation from the battery poles and cable endsusing a brass brush. Tighten the cable ends and pro-tect them using pole grease or Vaseline.
Electrolyte level
The Electrolyte level should be 5–10 mm over the cellplates in the battery. Add battery water as needed.
After filling the batteries should be charged by beingconnected to a battery charger, or by running the en-gine in normal operation for at least 30 minutes.
NOTE! Certain maintenance-free batteries have spe-cial instructions that must be followed.
IMPORTANT! Never switch the batteries + poleand - pole.
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Batteries, charging
WARNING! Explosion risk. During charging oxy-hydrogen gas is formed. Short-circuits, openflame or sparks can cause a powerful explosion.Ventilate well.
WARNING! Battery electrolyte is strongly corro-sive. Protect eyes, skin and clothing. Alwaysuse safety glasses and gloves. In case of skincontact, wash with soap and large quantities ofwater. In case of eye contact rinse immediatelywith large quantities of water and contact a doc-tor as soon as possible.
Charge batteries if they have become discharged. Ifthe engine is not used for an extended period the bat-teries should be fully charged initially and receive peri-odic maintenance charging (see the battery manufac-turers recommendations). A discharged statedamages batteries and they can also freeze and breakduring cold weather.
IMPORTANT! Carefully follow all instructions forthe battery charger. To avoid risk for electro-chemical corrosion when using an externalcharger when an external charger is used thebattery cables should be removed from the bat-tery before the charger is connected.
During charging the cell plugs should be unscrewedbut remain in the plugholes. Ventilate well, especiallyif the battery is being charged in an enclosed space.
WARNING! Always turn off the charger beforeloosening the charging clamps. Never confusethe + and - poles of the batteries. Risk of caus-ing sparks and explosion.
There are special instructions for so-called quick-charging. Quick-charging can shorten the useful lifeof the battery and should therefore be avoided.
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Conservation
• For periods of storage up to 8 months:
Change the engine oil and oil filter and then run untilwarm.
For periods of storage longer than 8 months:
Preserve the lubrication and fuel systems with pres-ervation oil. See instructions on next page.
• Make sure that the coolant’s freeze protection issufficient. Supplement as needed. As an alternativethe coolant can be drained (drain also the coolantfilter).
• Drain off any water and contamination from the fuelfilter and the fuel tank. Fill the tank completely fullwith fuel to avoid building of condensation.
• Disconnect the battery cables and clean and chargethe batteries. Maintenance charge the batteries peri-odically during the storage period. A poorlycharged battery can freeze and break.
• Clean the engine externally. Do not use high-pres-sure spray when cleaning the engine. Touch-uppaint damage using Volvo Penta original paint.
• Spray the electrical system’s components with awater displacing spray.
• Check and treat control cables using rust-preventa-tive.
• Affix a note on the engine showing the date, type ofpreservation and type of preservation oil is pro-vided.
• Cover the air filter, exhaust pipe and the engine ifcalled for.
To prevent the engine and other equipment from suffering damage during periods of storage exceeding twomonths a preservation procedure should be performed. It is important that this be done correctly and that no partof it be forgotten. We have therefore created a checklist covering the most important points.
Before the engine is taken out of service for an extended period an authorized Volvo Penta service facility shouldperform a check.Problems should be addressed at this point so that the equipment will be ready for use when needed next.
WARNING! Prior to starting maintenance work the chapter ”Maintenance” should be read carefully. In it youwill find instructions for how the work can be carried out in a safe and correct manner
WARNING! Certain preservation oils are flammable. Some even produce dangerous fumes. Make sure thatthere is good ventilation. Use a protective mask when spraying.
IMPORTANT! When cleaning with a high-pressure sprayer the following instructions must be kept in mind:Never point the spray at seals, rubber hoses or electric components. Never use the high-pressure functionwhile cleaning the engine.
Preparation for storage
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Preservation of lubrication and fuel systems for storage exceeding 8 months:
• Drain the oil from the engine and fill it with pre-serving oil* to just over the MIN marking on thedipstick.
• Connect the suction and return fuel lines to acontainer filled with 1/3 preservation oil* and2/3 diesel fuel.
• Bleed the fuel system.
• Start the engine and operate at a high idlespeed until approximately two liters have beenused. Shut off the engine and connect the nor-mal fuel lines.
• Empty the preservation oil from the engine.
• Follow otherwise the instructions on the previ-ous page.
*Preservation oil is distributed by oil manufacturers.
Removing conservationpreparations
• Remove any covers from the engine, air filter andexhaust pipe.
• Fill the engine with the proper grade of lubricatingoil as needed. Mount a new oil filter if a filterchange was not performed in conjunction with thepreservation process.
• Mount a new fuel filter and purge the fuel system.
• Check the drive belt/s.
• Check the condition of the hoses and check-tighten the hose clamps.
• Close the drain valves and replace any drainplugs.
• Check the coolant levels. Add as needed.
• Connect the fully charged batteries.
• Start the engine and run until warm at a high idlespeed prior to apply load to the engine.
• Check that no leakage of oil, fuel or coolantoccurs.
Preparation for storage
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1. Discharged batteries
2. Poor connection/broken wires
3. Main switch turned off
4. Fuse on the wiring box blown
5. Malfunctioning start lock
6. Malfunctioning main relay
7. Malfunctioning starter motorrelay
8. Malfunctioning starter motor/solenoid
9. Out of fuel:- fuel valves closed- fuel tank empty/wrong tankconnected
10. Blocked fuel filter/pre-filter(because of contamination orparaffin condensation in thefuel at low temperatures)
Troubleshooting
Symptoms and possible causes
Diagnostic button’s indicator is blinking See the chapter ”Diagnostic function”.
The engine can not be stopped 2, 5
The starter motor does not turn over 1, 2, 3, 4, 5, 6, 7, 8, 25
The starter motor turns slowly 1, 2
The starter motor turns normally but the engine does not start 9, 10, 11, 12,13
The engine starts but stops again 9, 10, 11, 12, 14
The engine does not reach the correctoperational RPM with full throttle 10, 11, 12, 13, 14, 15, 22, 26, 27, 28
The engine does not run smoothly 11, 12, 13
Poor fuel economy 13, 14, 16, 26
Black exhaust smoke 13, 14
Blue or white exhaust smoke 15, 16, 23
Insufficient lubricating oil pressure 17
Excessive coolant temperature 18, 19, 20, 21
Insufficient coolant temperature 21
Absent or poor charging 2, 24
A number of symptoms and possible causes for engine problems are described in the table below. Always contactyour Volvo Penta dealer if problems occur that you are not able to solve on your own.
WARNING! Read through the safety instructions for maintenance and service work in the chapter ”Safety in-formation” before starting to work.
11. Air in the fuel system
12. Water/contamination in thefuel
13. Malfunctioning injector(injectors)
14. Insufficient air to the engine:- blocked air filter- air leakage between theturbo and the engine intake
plenum- contaminated compressorsection in the turbocharger- malfunctioning turbocharger- poor engine compartment
ventilation
15. Excessive coolant tempera-ture
16. Insufficient coolant tempera-ture
17. Insufficient lubrication oil level
18. Low coolant level
19. Air in the fresh water coolantsystem
20. Malfunctioning circulationpump
21. Defective thermostat
22. Blocked intercooler
23. Excessive lubricating oil level
24. Generator drive belt slippage
25. Water inside the engine
26. High backpressure in theexhaust system
27. High oil temperature
28. High charge-air temperature
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Diagnostic function
• Fault codes can also be read by means of theVODIA tool. Please refer to the “VODIA User’sGuide” for advice on use.
At the same time, the fault is stored in the control unitmemory. When the fault has been attended to and theignition is switched off and on again, the fault disap-pears as active.
Inactive faults• DCU - the fault is indicated as passive
• CIU - the diagnostic lamp goes out
• DU - the fault message disappears (inactive faultscan not be read out)
• “Easy Link” - the lamp on the alarm panel goes out
Effect on engineEngines are affected differently, depending on the se-verity of the fault discovered by the diagnostic function.
A fault message in the form of a fault code is alwaysgenerated when a malfunction is discovered by the di-agnostic function.
Engines are affected differently, depending on the se-verity of the fault.
• The engine is not affected
• Engine idles
• Engine torque is restricted to a certain amount
• Engine is stopped
Message regarding disturbanceIf the diagnostic function discovers a malfunction inthe EMS-2 system, this is reported by means of faultcodes/fault messages on the instruments.
Both active (un-mended) and passive (mended) faultsare stored in the control unit.
Please refer to the “Operation” heading for readingfault codes/fault messages.
All fault codes and fault messages are found in thefault code list, with information about the reason, reac-tion and measures to be taken. Please refer to the“Fault codes” chapter.
NOTE! All instruments are optional
Active faultsDCU (Display Control Unit)
• text “!! ENGINE WARNING !!” is shown on thedisplay.
NOTE! It’s possible to choose which language the in-formation will be presented in.
CIU (Control Interface Unit)
• the diagnostic lamp starts to flash.
• “Easy Link” instrument (only with CIU)
- the relevant lamp on the alarm panel lights up
- after the diagnostic button has been pressed,the fault code is shown as text on the tachometerdisplay.
DU (Display Unit)
• Either “WARNING!” or “ALARM STOP” (a hornsounds) will be shown on the display, dependingon the severity of the fault.
NOTE! You can choose the language that the informa-tion is presented in.
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
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53
Reading fault causes via the DCU(Display Control Unit)When a fault code is set, the following text is shownon the display:
“!! ENGINE WARNING !!”
alternated with
“Press SEL for information”.
NOTE! You can choose the language used for the in-formation presented on the.
Read the fault code as follows:
1. Press the SEL button (to come to the fault list.The fault list shows:- Operation hours- Fault message- Active/inactive
2. Look up the fault code in the “Fault Code” chapterand take the recommended measures.
3. Press the ESC button to leave the fault list.
NOTE! To enter the fault list when no fault code hasbeen set, press the SEL button and select “Diagnos-tics” from the menu.
Reading fault codes via the DU (DisplayUnit)Depending on the severity of the fault, the following textwill appear on the display: “WARNING!” or “ALARMSTOP” (a horn sounds).
1. Press any button to come to the fault list.
The fault list shows:- Operation hours- Fault message
2. Look up the fault code in the “Fault Code” chapterand take the recommended measures.
3. Press ACK to confirm the fault code. The displaybackground will change color (the buzzer stopssounding).
4. Press EXIT to leave the fault list.
OperationWhen a malfunction has occurred and the diagnosticsystem has generated one or more fault codes, theseare read out differently, depending on the equipmentused. Please refer to “Fault codes”.
If the system indicates that a fault code has been set:
1. Cut engine speed to idle, or shut the engine off.
2. For DCU/DURead the fault code that has been set from thedisplay, please refer to “Reading fault codes viathe DCU” or “Reading fault codes via the DU”.
For CIUpress the diagnostic button and read the faultcode that has been set, by observing the flashingof the diagnostic lamp. Please refer to “Readingfault codes via the diagnostic lamp, CIU”
3. Look up the fault code in the “Fault Code” chapterand take the recommended measures.
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Erasing fault codesFault codes must be erased by means of the VODIAtool.
Reading fault codes via the diagnosticlamp on the instrument panel, CIUWhen the system has discovered a malfunction, thediagnostic lamp starts to flash. If the diagnostic but-ton is depressed and then released, a fault code isflashed out.The fault code consists of two groups of flashes, sep-arated by a pause of two seconds. A fault code is ob-tained by counting the number of flashes in eachgroup.
Example: pause = Fault code 2.4
The fault code is stored and can be read as long asthe malfunction remains. You can find informationabout cause, reaction and actions in the “Fault Code”chapter.
Read the fault code as follows:
1. Press the diagnostic button.
2. Release the diagnostic button and make a note ofthe fault that is flashed out.
3. Repeat items 1-2. A new fault code is flashed outif more are stored. Repeat until the first fault codeis repeated.
NOTE! When the first fault code is repeated, all faultcodes have been read out.If the diagnostic button is pressed after the fault hasbeen mended and the fault codes have been erased,code 1.1 “No fault” will be displayed.
Reading the fault codes via an “Easylink” instrument (only with a CIU)When the system has discovered a malfunction, thisis reported by the diagnostic lamp which starts toflash.
1. Press the diagnostic button. The fault code isshown as text on the tachometer display.
2. Look up the fault code in the “Fault Code” chapterand take the recommended measures.
3. When the fault has been rectified, the fault codedisappears from the display and the diagnosticlamp goes out.
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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 bythe diagnostic lamp. PID 97 is read with the VODIA diagnostic tool. With the use of DCU or DU the fault mes-sage will be shown as text in the display.
NOTE! Please refer to ”Wiring schedule CIU and DCU” for references to the sleeves in the electrical connectorson the engine control unit.
Code 1.1 No faults
There are no active faults.
Code 2.1, PID / SPN 97. Water in fuel
Cause:
• Water in fuel.
Reaction:
• None.
Remedy:
• Empty the primary fuel filter.
Code 2.2, PID / SPN 111. Coolant level
Cause:
• Low coolant level.
Reaction:
• Engine control module reduces engine power (un-less the protection has been shut off with theVODIA diagnostic tool).
• Engine stopped.
Remedy:
• Check the coolant level.
• Check coolant level monitor function.
Code 2.3, PID / SPN 111. Coolant level sensor
Cause:
• Short circuit to positive (+).
• Fault in sensor.
Reaction:
• None.
Remedy:
• Check that the coolant level sensor cable is notdamaged.
• Check coolant level sensor function.
Code 2.4, SID22 / SPN 637Flywheel speed sensor
Cause:
• No signal.
• Abnormal frequency.
• “Intermittent” signal from the sensor.
• Fault in sensor.
Reaction:
• Engine is very difficult to start and runs roughlywhen it starts.
Remedy:
• Check that the sensor connector is correctly in-stalled.
• Check that the engine speed sensor cable is notdamaged.
• Check that the engine speed sensor is correctlyinstalled in the flywheelhousing.
• Check engine speed sensor function.
Code 2.5, SID21 / SPN 636Camshaft drive speed sensor
Cause:
• No signal.
• Abnormal frequency.
• Fault in sensor.
Reaction:
• Engine takes longer to start than normal. Engineruns normally when running.
Remedy:
• Check that the engine speed sensor connector iscorrectly installed.
• Check that the engine speed sensor cable is notdamaged.
• Check that the engine speed sensor is correctlyinstalled in the upper timing gear cover.
• Check engine speed sensor function.
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Fault codes
56
Code 2.6, PID / SPN 190. Engine speed
Cause:
• Engine speed too high.
Reaction:
• None.
Remedy:
• After the engine has stopped, look for the reasonfor the high speed.
Code 2.8, PPID 132 / SPN 608Speed potentiometer connected to CIU
Cause:
• Shorted to plus (+) or minus (-).
• Fault in sensor.
Reaction:
• Engine goes to idle.
• If you release the accelerator first, and the pressit down again, the engine can be forced to run us-ing the idle contact.
Remedy:
• Check that the potentiometer has been connectedcorrectly.
• Check that the cable harness to the potentiometerhas not been damaged.
• Check the potentiometer function.
Code 2.9, PID / SPN 97Indicator for water in fuel
Cause:
• Short circuit
• Open circuit.
• Fault in indicator.
Reaction:
• None.
Remedy:
• Check the indicator cables for breaks and shortcircuits.
• Check indicator function. Change indicator as nec-essary
Code 3.1, PID / SPN 100. Oil pressure sensor
Cause:
• Short circuit to positive (+) or earth (ground) (–).
• Open circuit.
Reaction:
• None.
Remedy:
• Check that the oil pressure sensor cable is notdamaged.
• Check that the oil pressure sensor is correctlyconnected.
Code 3.2, PID / SPN 105Boost temperature sensor
Cause:
• Short circuit to positive (+) or earth (ground) (–).
• Open circuit.
Reaction:
• None.
Remedy:
• Check that the boost temperature sensor connec-tor is correctly installed.
• Check that the boost temperature sensor cable isnot damaged.
• Check that the boost temperature sensor is cor-rectly installed.
• Check boost temperature sensor function.
Code 3.3, PID / SPN 110Coolant temperature sensor
Cause:
• Short circuit to positive (+) or earth (ground) (–).
• Open circuit.
Reaction:
• Preheating is also activated when the engine is hot.
Remedy:
• Check that the coolant temperature sensor con-nector is correctly installed.
• Check that the coolant temperature sensor cableis not damaged.
• Check that the coolant temperature sensor is cor-rectly installed.
• Check coolant temperature sensor function.
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Fault codes
57
Code 3.4, PID / SPN 106Boost pressure sensor
Cause:
• Short circuit to positive (+) or earth (ground) (–).
• Open circuit.
Reaction:
• Engine smokes more than normally during accel-eration/load increase.
Remedy:
• Check that the boost pressure sensor connectoris correctly installed.
• Check that the boost pressure sensor cable is notdamaged.
• Check that the boost pressure sensor is correctlyinstalled.
• Check boost pressure sensor function.
Code 3.5, PID / SPN 10. Boost pressure
Cause:
• Boost pressure too high
Reaction:
• Engine control module reduces engine power (un-less the protection has been shut off with theVODIA diagnostic tool).
Remedy:
• Check turbocharger compressor function.
• Check boost pressure sensor function.
• Check fuel volume/injector.
Code 3.6, PID / SPN 94. Fuel pressure sensor
Cause:
• Short circuit to positive (+) or earth (ground) (–).
• Open circuit.
Reaction:
• None.
Remedy:
• Check that the fuel pressure sensor connector iscorrectly installed.
• Check that the fuel pressure sensor cable is notdamaged.
• Check that the fuel pressure sensor is correctlyinstalled.
• Check fuel pressure sensor function.
Code 3.7, PID / SPN 175. Oil temperature sensor
Cause:
• Shorted to plus (+) or minus (-).
• Break.
Reaction:
• None.
Remedy:
• Check that the cable harness to the oil tempera-ture sensor has not been damaged.
• Check that the oil temperature sensor has beenconnected correctly.
Code 3.8, PID / SPN 94. Fuel pressure
Cause:
• Low supply pressure.
Reaction:
• None.
Remedy:
• Check if it is possible to build up pressure withthe hand pump.
• Check the fuel filter.
• Check the fuel pre-filter.
Code 3.9, PID / SPN 158. Battery voltage, EMS
Cause:
• Faulty alternator.
• Faulty battery, battery cables.
Reaction:
• None.
Remedy:
• Check the supply voltage from the control unit.
Code 4.6, PPID 3 / SPN 677Start output / Start motor relay
Cause:
• Shorted to plus (+) or minus (-).
• Activated for too long.
Reaction:
• The engine cannot be started.
• The engine starts immediately when ignition is tur-ned on.
Remedy:
• Check that connections to the ignition key havenot been damaged.
• Check that the cable harness to the ignition keyhas not been damaged.
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Fault codes
58
Code 4.8, PPID 6/ SPN 520195. Stop input EMS
Cause:
• Short circuit to negative (-).
• Open circuit.
Reaction:
• Engine can only be stopped with the auxiliarystop.
Remedy:
• Check that the starter switch connections are notdamaged.
Code 5.2, PPID 4 / SPN 520194. Starter input CIU
Cause:
• Shorted to minus (-).
• Activated for too long.
Reaction:
• The engine cannot be started.
• The engine starts immediately when ignition is tur-ned on.
Remedy:
• Check that connections to the ignition key havenot been damaged.
• Check that the cable harness to the ignition keyhas not been damaged.
Code 5.3, PPID 6/ SPN 970. Stop input CIU
Cause:
• Short circuit to negative (-).
• Open circuit.
• Activated for too long time.
Reaction:
• Engine can only be stopped with the auxiliary stop(AUX STOP) on engine.
• Engine stops. A fault code is displayed for 40seconds and the engine can not be started duringthis time. When a fault code is active, the enginecan be started but not stopped.
Remedy:
• Check that the starter switch connections are notdamaged.
• Check that the ignition switch cable is notdamaged.
Code 5.4, PID 45/ SPN 626. Preheating relay
Cause:
• Short circuit to positive (+) or earth (ground) (–).
• Open circuit.
Reaction:
• Preheating can not be activated.
• Preheating is constantly connected.
Remedy:
• Check that the relay input cable is not damaged.
• Check relay function.
Code 5.5, PID / SPN 107, Air filter pressure
Reason:
• Too large pressure drop across filter.
Reaction:
• Less good response from engine.
Action:
• Check the air filter.
Code 5.6, PID/SPN 107. Air filter sensor
Cause:
• Shorted to plus (+) or minus (-).
• Break.
Reaction:
• None
Remedy:
• Check that the air filter sensor contact is correctlyinstalled.
• Check that the cable harness to air filter sensorhas not been damaged.
• Check the air filter sensor functionality.
Code 5.7. PID / SPN 98, Oil level
Cause:
• Oil level is too low.
Reaction:
• Warning indication.
Remedy:
• Check the oil level.
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Fault codes
59
Code 5.8, PID / SPN 175. Oil temperature
Cause:
• Oil temperature is too high
Reaction:
• Warning indication.
• The engine control module limits engine output(unless protection has been turned off with thediagnosis tool VODIA).
Remedy:
• Check the oil level.
• Check the oil temperature.
• Check the oil temperature sensor function.
Code 5.9, PID / SPN 98. Oil level sensor
Cause:
• Shorted to plus (+) or minus (-).
• Break.
Reaction:
• None.
Remedy:
• Check that the cable harness to the oil level sen-sor has not been damaged.
• Check the oil level sensor function.
Code 6.1, PID / SPN 110. Coolant temperature
Cause:
• Coolant temperature is too high.
Reaction:
• Engine control module reduces engine power (un-less the protection has been shut off with theVODIA diagnostic tool).
Remedy:
• Check the coolant level.
• Check the intercooler (cleanliness).
• Check if there is air in the cooling system.
• Check the pressure cap on the expansion tank.
• Check coolant temperature sensor function.
• Check thermostat function.
Code 6.2, PID / SPN 105. Boost temperature
Cause:
• Boost temperature is too high.
Reaction:
• Engine control module reduces engine power (un-less the protection has been shut off with theVODIA diagnostic tool).
Remedy:
• Check the coolant level.
• Check the intercooler (cleanliness).
• Check boost temperature sensor function.
• Check the function of the thermostat.
Code 6.4, PPID 231 / SPN 639, Data link (CAN),CIU
Cause:
• Faulty data link (CAN), CIU.
Reaction:
• Instruments and warning lamps stop working.
Remedy:
• Check that the 8-pin connector is not damaged.
• Check that the cables between the CIU and theengine management unit are not damaged.
Code 6.5, PPID 231 / SPN 639, 2017 / PSID 201Data link (CAN), EMS 2
Cause:
• Internal fault in control module.
Reaction:
• Engine not operating: engine can not be started.Engine operating: engine idles and can only bestopped with the auxiliary stop (AUX-stop).
Remedy:
• Check that the 8-pin connector is not damaged.
• Check that the cables between the CIU and theengine management unit are not damaged.
• Check that sleeves 11 and 12 in the connector onthe CIU are not damaged.
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Fault codes
60
Code 6.6, PID / SPN 100, Oil pressure
Cause:
• Oil pressure is too low.
Reaction:
• Engine control module reduces engine power (un-less the protection has been shut off with theVODIA diagnostic tool).
Remedy:
• Check oil level.
• Check that the air filters are not blocked.
• Check system pressure valves and safety valvesin the oil system.
• Check oil pressure sensor function.
Code 6.7, PPID 8 / SPN 520192,Piston cooling pressure
Cause:
• Piston cooling pressure is too low.
Reaction:
• Engine stopped. The fault code is de-activated atengine speeds below 1000 rpm.
Remedy:
• Check that the oil pressure in the engine exceeds175 kPa (25.4 psi).
Code 6.8, PPID 8 / SPN 520192,Piston cooling pressure sensor
Cause:
• Shorted to plus (+) or minus (-).
• Break.
Reaction:
• None.
Remedy:
• Check that the piston cooling pressure sensorcontact is correctly installed.
• Check that the cable harness to the piston coolingpressure sensor has not been damaged.
• Check the piston cooling pressure sensor func-tionality.
Code 6.9, PID / SPN 158, Battery voltage, CIU
Cause:
• Short circuit to negative (-).
• Faulty alternator.
• Faulty battery, battery cables.
Reaction:
• Problems in engine starting.
Remedy:
• Check the supply voltage from the control unit.
• Check the battery.
• Check the alternator.
• Check the 8-pin contact.
Code 7.1, SID 1 / SPN 651Injector, cylinder #1
Cause:
• Electrical fault.
• Faulty compression or injector.
Reaction:
• Engine runs on 5 cylinders.
• Abnormal sound.
• Reduced performance.
Remedy:
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-aged.
• Check fuel supply pressure.
• Check the valve clearance.
• Do a compression test and check cylinder #1.
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Fault codes
61
Code 7.2, SID 2 / SPN 652Injector, cylinder #2
Cause:
• Electrical fault.
• Faulty compression or injector.
Reaction:
• Engine runs on 5 cylinders.
• Abnormal sound.
• Reduced performance.
Remedy:
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-aged.
• Check fuel supply pressure.
• Check the valve clearance.
• Do a compression test and check cylinder #2.
Code 7.3, SID 3 / SPN 653Injector, cylinder #3
Cause:
• Electrical fault.
• Faulty compression or injector.
Reaction:
• Engine runs on 5 cylinders.
• Abnormal sound.
• Reduced performance.
Remedy:
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-aged.
• Check fuel supply pressure.
• Check the valve clearance.
• Do a compression test and check cylinder #3.
Code 7.4, SID 4 / SPN 654Injector, cylinder #4
Cause:
• Electrical fault.
• Faulty compression or injector.
Reaction:
• Engine runs on 5 cylinders.
• Abnormal sound.
• Reduced performance.
Remedy:
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-aged.
• Check fuel supply pressure.
• Check the valve clearance.
• Do a compression test and check cylinder #4.
Code 7.5, SID 5 / SPN 655Injector, cylinder #5
Cause:
• Electrical fault.
• Faulty compression or injector.
Reaction:
• Engine runs on 5 cylinders.
• Abnormal sound.
• Reduced performance.
Remedy:
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-aged.
• Check fuel supply pressure.
• Check the valve clearance.
• Do a compression test and check cylinder #5.
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Fault codes
62
Code 7.6, SID 6 / SPN 656Injector, cylinder #6
Cause:
• Electrical fault.
• Faulty compression or injector.
Reaction:
• Engine runs on 5 cylinders.
• Abnormal sound.
• Reduced performance.
Remedy:
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-aged.
• Check fuel supply pressure.
• Check the valve clearance.
• Do a compression test and check cylinder #6.
Code 7.7, PID / SPN 153Crankcase ventilation pressure
Cause:
• Crankcase ventilation pressure too high.
Reaction:
• The engine is shut down (if the protection has notbeen shut off by the parameter tool).
Remedy:
• Check whether the crankcase ventilation is bloc-ked.
• Check whether cylinder liner, piston or piston ringsare worn or damaged.
Code 7.8, PID / SPN 153Crankcase ventilation pressure sensor
Cause:
• Shorted to plus (+) or minus (-).
• Break.
Reaction:
• None.
Remedy:
• Check that the crankcase ventilation pressuresensor contact is correctly installed.
• Check that the cable harness to the crankcaseventilation pressure sensor has not been dam-aged.
• Check crankcase ventilation pressure sensorfunction.
Code 7.9, PID / SPN 172Air temperature sensor, inlet
Cause:
• Shorted to plus (+) or minus (-).
• Break.
Reaction:
• None.
Remedy:
• Check that the air temperature sensor contact iscorrectly installed.
• Check that the cable harness to the air tempera-ture sensor has not been damaged.
• Check the air temperature sensor functionality.
Code 8.5, PPID 19 / SPN 2791. Internal EGR
Cause:
• Fault in cable harness (boost pressure sensor).
• Mechanical fault on the IEGR
Reaction:
• Engine control module reduces engine power.
Remedy:
• Check cable harness (boost pressure sensor).
• Check the IEGR.
Code 9.3, 232 / SPN 620/1079Power supply to sensor
Cause:
• Shortcut.
• Fault in sensor.
Reaction:
• Faulty values in oil pressure and boost pressuresensors.
• Fault code for oil pressure- and boost pressuresensor.
• Low engine output.
• The instrument shows zero oil pressure and boostpressure.
Remedy:
• Check that the cable harness to oil pressure andboost pressure sensor has not been damaged.
• Check oil pressure and boost pressure sensors.
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Fault codes
63
Code 9.8, SID 253 / SPN 630Data set memory EEPROM, CIU
Cause:
• Internal fault in control module
• Programming faulty.
Reaction:
• Engine does not start.
Remedy:
• Re-program the control module. If the fault re-mains, change the control module.
Code 9.8, SID 254 / SPN 629Fault in control unit, CIU
Cause:
• Faulty EEPROM, CIU.
• Faulty flash memory, CIU.
• Fault in control module, CIU
Reaction:
• CIU returns to factory setting.
• Engine goes to idle.
• Engine can not be started.
Remedy:
• Re- program the unit
• Change CIU unit.
Code 9.9, SID 240 / SPN 639. Memory fault
Cause:
• Memory fault in engine management system.
Reaction:
• Engine might not start.
Remedy:
• Re-program the unit.
Code 9.9, SID 253 / SPN 630Data set memory EEPROM, EMS
Cause:
• Internal fault in control module
• Programming faulty.
Reaction:
• Engine does not start.
Remedy:
• Re-program the control module. If the fault re-mains, change the control module.
Code 9.9, SID 254 / SPN 629Control module EMS
Cause:
• Internal fault in control module.
Reaction:
• Engine misfires.
• Engine does not start.
Remedy:
• Change engine control unit.
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64
General
Type designation TAD1250VE TAD1251VE TAD1252VE
Power See sales literature
Torque See sales literature
Number of cylinders 6 6 6
Cylinder diameter 131 131 131
Stroke, mm inch 150 150 150
Displacement, dm3 12,13 12,13 12,13
Dry weight, kg lbs 1230 1230 1230
Wet weight, kg lbs 1270 1270 1270
Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Compression ratio 18,1:1 18,1:1 18,1:1
Low idle, rpm 700 700 700
High idle, rpm 1900 1900 1900
Technical Data
Lubrication systemOilChange volume including change of three filters:With horizontal installation ......................................... 35 liter
Oil pressureat Operational speed 1100 rpm or higher .................... 400–550 kPa
Idle, min ..................................................................... 175 kPa
Oil grade .................................................................... See chapter ”Lubrication system”.Viscosity .................................................................... See chapter ”Lubrication system”.
Oil filter
Number ...................................................................... 3Full-flow filter(tightened 1/2–3/4 turn after sealing surface contact) . 2Bypass filter(tightened 3/4–1 turn after sealing surface contact) .... 1
Oil pumpType .......................................................................... Gear driven
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65
Technical data
Fuel specificationThe fuel must at least satisfy national and international standards for market fuel, for example:
EN 590 (with nationally adjusted environmental and temperature requirements)
ASTM-D975 No. 1-D and 2-D
JIS KK 2204
Sulfur content: According to legal requirements in each respective country.
Low-density fuel (urban diesel in Sweden and citydiesel in Finland) can cause a power reduction of approximately 5%and a decrease in fuel economy of approximately 2–3%.
Cooling systemType .......................................................................... Overpressure, closedPressure valve opens at ............................................ 75 kPa (11 psi)Volume (engine) ......................................................... 20 liters (5.3 US gal)Volume (engine + radiator and hoses) ........................ 44 liters (11.6 US gal)
ThermostatType .......................................................................... Piston thermostatNumber ...................................................................... 1Opening temperature .................................................. 82°C (180°F)
Coolant filterNumber ...................................................................... 1
Injection orderInjection order ............................................................ 1-5-3-6-2-4
Feed pumpFeed pressure after fuel filter at1000 RPM, min. ......................................................... 350 kPa (51 psi)Feed pressure after fuel filter atfull load, min. ............................................................. 350 kPa (51 psi)
Overflow valveOpening pressure ....................................................... 400–450 kPa (58–65 psi)
Fuel system
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Technical data
66
Electrical systemSystem voltage .......................................................... 24 VAlternator:
voltage/max. current .............................................. 28 V/80 Apower approx. ........................................................ 2200W
Battery capacity ........................................................ 2 serial-connected 12 V, max. 220 AhBattery electrolyte density at +25°C:
fully charged battery .............................................. 1.28 g/cm3 (1.24 g/cm3)*the battery discharges at ........................................ 1.24 g/cm3 (1.20 g/cm3)*
* Note! Applies to batteries with tropical electrolyte.
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Notes
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Notes
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Please note that this offer is valid for 12 months from the date of deliv-ery of the engine, after this it is subject to availability.
Post or fax this coupon to:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSwedenFax: +46 31 545 772
Orders can also be placed viathe Internet:http://www.volvopenta.com/manual/coupon
Yes please,I would like an operator’s manual in English at no charge.
Publication number: 7745086
Name
Address
Country 4220
0/61
5001
/155
0999
0019
2
✂
Bitte beachten Sie, dass das Angebot für die Dauer von 12 Monaten ab demLieferdatum des Motors gilt, danach nur noch bis zum Aufbrauchen des Lager-bestandes.
Schicken Sie den Couponper Post oder als Fax an:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSchwedenFax: +46 31 545 772
Die Bestellung kann auch überdas Internet erfolgen:http://www.volvopenta.com/manual/coupon
Ja danke,ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.
Publikationsnummer: 7745087
Name
Anschrift
Land 4220
0/61
5001
/155
0999
0019
2
✂
Noter que l’offre est valable 12 mois à partir de la date de livraison dumoteur, puis seulement dans la mesure des stocks disponibles.
Envoyez ou faxez le bon decommande à:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSuèdeFax: +46 31 545 772
Vous pouvez également passerla commande par Internet:http://www.volvopenta.com/manual/coupon
Oui merci,Je souhaite recevoir un manuel d’instructions gratuit en français.Numéro de publication: 7745088
Nom
Adresse
Pays 4220
0/61
5001
/155
0999
0019
2
✂
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Notare che la validità dell’offerta è garantita solo per 12 mesi dalla consegna delmotore, dopodiché si procederà fino ad esaurimento scorte.
Spedire il tagliando per posta oper fax a:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSveziaFax: +46 31 545 772
L’ordinazione può essere fattaanche su Internet:http://www.volvopenta.com/manual/coupon
Sì, grazie,desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana.
Public. No.: 7745091
Nome e Cognome
Indirizzo
Paese 4220
0/61
5001
/155
0999
0019
2
✂
Observe que la oferta es válida durante 12 meses a partir de la fecha de entregadel motor. A partir de la fecha de finalización de la oferta, la misma es válida siem-pre que haya existencias.
Franquear o enviar fax a:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSueciaFax: +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: 7745089
Nombre
Direc
País 4220
0/61
5001
/155
0999
0019
2
✂
Observera att erbjudandet gäller i 12 månader från motornsleveransdatum, därefter endast i mån av tillgång.
Posta eller faxa kupongen till:Dokument & Distribution centerOrdermottagningenARU2, Avd. 64620SE-405 08 GöteborgSverigeFax: +46 31 545 772
Beställningen kan även görasvia internet:http://www.volvopenta.com/manual/coupon
Ja tack,jag vill kostnadsfritt ha en instruktionsbok på svenska.
Publikationsnummer: 7745085
Namn
Adress
Land 4220
0/61
5001
/155
0999
0019
2
✂
7745
086
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ownl
oade
d fr
om w
ww
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nta.
com
16/
03/2
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16:5
7:37
Denk eraan dat het aanbod geldt gedurende 12 maanden na de datumwaarop de boot werd afgeleverd, daarna alleen indien nog verkrijgbaar.
Stuur of fax de coupon naar:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgZwedenFax: +46 31 545 772
U kunt ook bestellen viainternet:http://www.volvopenta.com/manual/coupon
Ja graag,Ik wil kosteloos een instructieboek in het Nederlands ontvangen.
Publicatienummer: 7745093
Naam
Adres
Land 4220
0/61
5001
/155
0999
0019
2
✂
Huomaa, että tarjous on voimassa 12 kuukautta veneen toimituspäivä-määrästä lukien ja sen jälkeen vain niin kauan kuin kirjoja riittää.
Postita tai faksaa kuponkiosoitteella:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgRuotsiFax: +46 31 545 772
Tilauksen voi tehdä myösInternetissä:http://www.volvopenta.com/manual/coupon
Kyllä kiitos,haluan suomenkielisen ohjekirjan veloituksetta.
Julkaisunumero: 7745092
Nimi
Osoite
Maa 4220
0/61
5001
/155
0999
0019
2
✂
Observar que esta oferta é válida durante um período de 12 meses a contar dadata de entrega do barco. Após este período, a oferta está dependente do númerode exemplares disponíveis.
Envie o talão pelo correio ouum fax para:Document & Distribution CenterOrder DepartmentARU2, Dept. 64620SE-405 08 GöteborgSuéciaFax: +46 31 545 772
A encomenda também podeser feita através da Internet:http://www.volvopenta.com/manual/coupon
Sim, obrigado(a)!Gostaria de receber gratuitamente um manual de instruções em português.
Número de publicação: 7745094
Nome
Endereço
País 4220
0/61
5001
/155
0999
0019
2
✂
7745
086
- D
ownl
oade
d fr
om w
ww
.vol
vope
nta.
com
16/
03/2
010
16:5
7:37
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nta.
com
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nta.
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AB Volvo PentaSE-405 08 Göteborg, Sweden
www.volvopenta.com
