OPERATOR’S MANUAL - Forkliftcenter · Safety texts in the Operator’s Manual have the following order of priority: DANGER! ,QGLFDWHV D KD]DUGRXV VLWXDWLRQ ZKLFK LI QRW DYRLGHG

OPERATOR’S MANUALTAD560VE, TAD561VE

TAD761VE, TAD762VE, TAD763VE, TAD764VE, TAD765VE

EATS (EPA/CARB)

This Operator’s Manual may be ordered in a different lan-guage free of charge up to 12 months after delivery, via internet.http:// manual.volvopenta.com/coupon/If internet access isn‘t possible, please contact your Volvo Penta dealer.

Diese Betriebsanleitung kann bis zu 12 Monate nachder Lieferung über Internet kostenlos in einer anderenSprache bestellt werden. http:// manual.volvopenta.com/coupon/Wenn Sie keinen Internet-Zugriff haben, kontaktierenSie bitte Ihren Volvo Penta-Händler.

Ce manuel d‘utilisation peut être commandé gratuitement sur Internet en différentes langues, jusqu‘à 12 mois après la date de livraison.http:// manual.volvopenta.com/coupon/Veuillez contacter votre Distributeur Volvo Penta si vous avez un problème d‘accès à l‘Internet.

El presente libro de instrucciones puede solicitarse en otro idioma diferente, libre de cargo, hasta 12 meses después de la entrega, mediante internet.http:// manual.volvopenta.com/coupon/Si no se tiene acceso a internet, contacten al su concesionario Vol-vo Penta.

Denna instruktionsbok kan beställas via internet på ett annat språk gratis i upp till 12 månader efter leverans.http:// manual.volvopenta.com/coupon/Kontakta din Volvo Penta-återförsäljare om du inte har tillgång till internet.

Dit instructieboek kan gratis via internet in een a dere taal worden besteld tot 12 maanden na aflevering.http:// manual.volvopenta.com/coupon/Als toegang tot het internet niet mogelijk is, neem dan contact op met uw Volvo Penta dealer.

Denne instruktionsbog kan bestilles gratis på et andet sprog via Internettet i op til 12 måneder efter leveringen.http:// manual.volvopenta.com/coupon/Hvis det ikke er muligt at bestille via Internettet, bedes du kontakte din Volvo Penta forhandler.

Tämä käyttöohjekirja on tilattavissa Internetin kautta veloi-tuksetta eri kielillä 12 kuukauden ajan toimituksen jälkeen.http:// manual.volvopenta.com/coupon/Jos sinulla ei ole Internet-yhteyttä, ota yhteys lähimpään Volvo Pen-ta jälleenmyyjään.

Este Manual do Operador pode ser encomendad em idi-omas diferentes isento de custos até 12 meses após entrega, via internet.http:// manual.volvopenta.com/coupon/Se não for possível aceder à internet, contacte o seu concessi-onário Volvo Penta.

To παρόν Βιβλίο Χρήσης μπορεί να παραγγελθεί δωρεάν σε άλλη γλώσσα μέχρι 12 μήνες μετά την παράδοση,μέσω διαδικτύου.http:// manual.volvopenta.com/coupon/Εάν δεν είναι δυνατή η πρόσβαση στο ιαδίκτυο,παρακαλούμε επικοινωνήστε με το δικό σας αντιπρόσωπο της Volvo Penta.

Данное руководство по эксплуатации можно бес-платно заказать на другом языке по Интернету в течение 12 месяцев после доставки.http:// manual.volvopenta.com/coupon/Если доступ к Интернету отсутствует, обратитесь к своему дилеру компании Volvo Penta.

Bu Kullanım Kılavuzu, teslimden 12 ay sonrasına kadar İnternet yoluyla ücretsiz olarak farklı bir dilde sipariş edilebilir.http:// manual.volvopenta.com/coupon/İnternet mümkün değilse, lütfen Volvo Penta yetkili satıcınızla tmasa geçin.

Il manuale per l‘operatore può essere ordinato tramiteIn-ternet, in varie lingue e per consegna gratuita, entro 12 mesi dalla consegna del prodottohttp:// manual.volvopenta.com/coupon/Se l‘accesso a Internet risulta impossibile, contattare la concessio-naria Volvo Penta.

CALIFORNIA PROPOSITION 65 WARNING

Engine exhaust, some of its constituents, and a broad range of engine parts are known to the State of California to cause cancer, birth defects, and other re-productive harm. Additionally, lubricants, fuels, and other fluids used in engines – including any waste created through the wearing of engine parts – contain or produce chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Battery posts, terminals, and related accessories contain lead and lead compounds. Wash your hands after handling. Used engine oil contains chemicals that have caused cancer in laboratory animals. Always protect your skin by washing thoroughly with soap and water.

本操作手册可通过互联网以不同的言进行订购，交付后可免费使用达12 个月。http:// manual.volvopenta.com/coupon/如果无法访问互联网，请与沃尔沃遍达经销商联系。

Este Manual de operador pode ser encomendado em um idioma diferente, gratuitamente, até 12 meses após a entrega, via internet.http:// manual.volvopenta.com/coupon/Caso o acesso à internet não for possível, contatar seu distribuidor Volvo Penta.

このオペレーターズマニュアルの他言語版が、発行後最高

12か月間、インターネットより無料で発注可能です。http:// manual.volvopenta.com/coupon/インターネットにアクセスできない場合は、担当のボルボペンタディーラーまでご連絡ください。

من الممكن طلب دليل المشغل بلغة أخرى مجاًنا عبر اإلنترنت لفترة تصل إلى 12 شهًرا من بعد التسليم.

/http:// manual.volvopenta.com/coupon.Volvo Penta إذا كان الوصول إلى اإلنترنت غير متاح، فالرجاء االتصال بوكيل

Table of Content

Foreword ...................................................................................................... 3Safety Information ...................................................................................... 4Introduction ................................................................................................. 8

Emission Aftertreatment System ............................................................. 10Volvo Penta Dealer Network ................................................................... 11Volvo Penta Action Service ..................................................................... 11

Presentation .............................................................................................. 12Engines .................................................................................................. 12EMS (Engine Management System) .................................................... 13EATS (Exhaust Aftertreatment System) .............................................. 14

Major Components ............................................................................... 17Principle solution .................................................................................. 18Operation ............................................................................................. 21

Instruments and Controls ........................................................................ 23Display Control Unit .............................................................................. 23DU (Display Unit) ................................................................................... 29CIU (Control Interface Unit) .................................................................. 33Easy Link Instruments .......................................................................... 33

Optional ..................................................................................................... 34Stop/Start ............................................................................................... 34

Starting ...................................................................................................... 35Before Starting ...................................................................................... 35Starting the Engine ............................................................................... 36

DCU (Display Control Unit) .................................................................. 36Starting in Extreme Cold ...................................................................... 37Never Use Start Spray ......................................................................... 38Starting Using Auxiliary Batteries ......................................................... 38

Operation ................................................................................................... 39Reading the Instruments ...................................................................... 39Alarms .................................................................................................... 39Maneuvering .......................................................................................... 40

Operation at low load ........................................................................... 40Engine Shutdown ...................................................................................... 41

Before Engine Shutdown ..................................................................... 41Stop the Engine ..................................................................................... 41

Auxiliary stop ........................................................................................ 41After Engine Shutdown ........................................................................ 42

Fault Handling ........................................................................................... 43DCU (Display Control unit) ...................................................................... 43DU (Display Unit) .................................................................................... 43Easy Link Instruments ............................................................................. 44Erasing fault codes .................................................................................. 45Fault Tracing .......................................................................................... 46EATS Warnings and Inducements ....................................................... 48

Fault Code Register .................................................................................. 50Maintenance Schedule ............................................................................. 52Maintenance .............................................................................................. 53

Orientation ............................................................................................. 54Engine, General ..................................................................................... 55

Air Filter, Change ................................................................................. 56

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Charge Air Pipe, Leakage Check ......................................................... 57Drive Belt, Check and Change ............................................................. 58

Lubrication System ............................................................................... 59Oil level, checking and topping up ....................................................... 59Oil filter, Change .................................................................................. 60Engine Oil, Change .............................................................................. 61

Fuel System ........................................................................................... 62Draining condensate, fuel system ........................................................ 62Engine Fuel Filter Replacement ........................................................... 63Fuel Pre-filter, Change ......................................................................... 64Fuel system, bleeding .......................................................................... 65

Cooling System ..................................................................................... 66Coolant Level, Checking and Topping Up ........................................... 67Coolant, Draining ................................................................................. 68Charge Air Cooler, External Cleaning .................................................. 69Cooling System, Cleaning .................................................................... 69

Inlet and Exhaust System ..................................................................... 71Filling AdBlue®/DEF solution ............................................................... 71AdBlue/DEF Tank, Cleaning ................................................................ 73

Electrical System .................................................................................. 76Main switch .......................................................................................... 76Fuses ................................................................................................... 76Electrical Connections ......................................................................... 76Battery .................................................................................................. 77

Storage ....................................................................................................... 79Technical Data ........................................................................................... 81

Engines .................................................................................................. 81Lubrication System ............................................................................... 82

Oil Grade and Oil Change Interval ....................................................... 82Viscosity ............................................................................................... 82

Fuel System ........................................................................................... 83Cooling System ..................................................................................... 85

Water Quality ....................................................................................... 85Electrical System .................................................................................. 86Identification Numbers ......................................................................... 87

Index ........................................................................................................... 91

2 47704198 09-2016 © AB VOLVO PENTA

ForewordVolvo Penta engines are used all over the world. They are used in all possible operating conditions. This is not acoincidence. After 100 years as an engine manufacturer the Volvo Penta name has become a symbol of reliability,technical innovation, top-of-the-range performance and long service life. We also believe that this is what youdemand and expect of your Volvo Penta engine.

We would like you to read this operator’s manual thoroughly and follow the instructions we give on running andmaintenance. Pay strict attention to the safety instructions contained in the manual.

We would also like to welcome you to our worldwide network of dealers and service workshops to assist you withtechnical advice, service requirements and replacement parts. Please contact your nearest authorized VolvoPenta dealer for assistance.

Find your nearest dealer and a lot of other useful information by paying us a visit on our website atwww.volvopenta.com

47704198 09-2016 © AB VOLVO PENTA 3

Safety InformationRead the Operator’s Manual through very carefully before you start the engine or do any maintenance or service.It has to do with your safety; an incorrect operation can lead to personal injury and damage to products or property.This chapter describes how safety precautions are presented in the Operator’s Manual and on the product. It alsogives you an introduction to the basic safety rules for using and looking after the engine.If anything remains unclear or if you are unsure of something, contact your Volvo Penta dealer for assistance.

IMPORTANT:Always follow local safety instructions and regulations.

NOTICE! Check that you have received the correct Operator’s Manual before you read on. If not, please contactyour Volvo Penta dealer.

!This symbol is used in the Operator’s Manual and on the product, to call your attentionto the fact that this is safety information. Always read such information very carefully.

This symbol is used on our products in some cases and refers to important informationin the Operator’s Manual. Make sure that warning and information symbols on theengine are clearly visible and legible. Replace symbols which have been damaged orpainted over.

Safety texts in the Operator’s Manual have the following order of priority: DANGER!

Indicates a hazardous situation which, if not avoided, will result in death or seriousinjury.

WARNING!Indicates a hazardous situation which, if not avoided, could result in death or seriouspersonal injury.

CAUTION!Indicates a hazardous situation which, if not avoided, could result in minor or moderatepersonal injury.

IMPORTANT:Indicates a situation which, if not avoided, could result in property damage.

NOTICE! Used to draw your attention to important information that will facilitate thework or operation in progress.

4 47704198 09-2016 © AB VOLVO PENTA

Safety rules for operationDaily checksMake it a habit to give the engine and enginecompartment a visual check before the engine isstarted and after operations, once the engine hasstopped. This helps you to quickly discover fuel,coolant or oil leakages or any other abnormality thathas occurred, or is about to occur.

Carbon monoxide poisoningOnly start the engine in a well-ventilated area. Whenoperating in a confined space, exhaust fumes andcrankcase gases must be ventilated.

OperationThe engine must not be operated in environmentswhich contain explosive media since none of theelectrical and mechanical components are explosionproof.

Approaching a running engine is a safety risk. Hair,fingers, loose clothes, or dropped tools can catch onrotating components and cause severe injury.

When engines are supplied without safety guards, allrotating components and hot surfaces must beprotected after installation in their application, ifnecessary for personal safety.

Fuel fillingThere is always a risk of fire and explosion when fillingfuel. Smoking is forbidden, and the engine must bestopped.

Never overfill the tank. Close the tank cap securely.

Only use fuel recommended in the Operator’smanual. The wrong grade of fuel can cause seriousmalfunctions, power loss or engine shutdown.

Cooling SystemAvoid opening the coolant filling cap when the engineis hot. Steam or hot coolant can spray out and causeburns. At the same time the pressure built up is lost.

If the filler cap, coolant hose etc., have to be openedor removed when the engine is hot, undo the filler capslowly and carefully, to let the pressure out beforeremoving the filler cap completely and starting work.Note that the coolant can still be hot and causescalding.

Hot surfaces and fluidsA hot engine always increases the risk for burns. Beon your guard against hot surfaces: exhaust manifold,turbocharger, oil sump, charge air pipe, engine pre-heater, hot coolant and hot lubricating oil in pipes,hoses etc.

Safety Information

47704198 09-2016 © AB VOLVO PENTA 5

Care and maintenanceCompetenceNever carry out a job if you are not entirely sure howto do it. Contact your Volvo Penta dealer and ask forassistance instead.

Literature for more major tasks is available from yourVolvo Penta dealer.

Prevent startPrevent the engine from being started by removingthe ignition key and disconnecting the power with themain switch. Lock them in the “Off” position.

If the instrument panel does not have an ignition key,the engine compartment must be lockable, to preventunauthorized persons from starting the engine.Alternatively, a lockable main switch may be used.

Stopping the engineStop the engine before opening or removing theengine hatch/hood. Service and maintenance workmust be done with the engine stopped unlessotherwise specified.

Fix a notice by the operator position to say that workis in progress.

Working with, or approaching a running engine is asafety risk. Hair, fingers, loose clothes, or droppedtools can catch on rotating components and causesevere injury. Volvo Penta recommends that allservice work which requires the engine to be runningbe done by an authorized Volvo Penta workshop.

Lifting the engineThe lifting eyes fitted on the engine must be used forlifting. Always check that the lifting devices are in goodcondition and that they have the correct capacity forthe lift (engine weight together with auxiliaries, iffitted). The engine must be lifted with an adjustablelifting boom for safe handling. All chains or cablesmust be parallel to each other and should be assquare as possible to the top of the engine. Note thatauxiliary equipment installed on the engine couldchange its center of gravity. Special lifting devicesmay then be needed to obtain the correct balance andsafe handling. Never carry out work on an engine thatis only suspended in a hoist.

Fuel and lubrication oilsAlways protect your hands when searching for leaks.Fluids which leak under pressure can force their wayinto body tissue and cause severe injury. There is arisk of blood poisoning (septicemia).

Only use the fuel recommended in the Operator’sManual. The wrong grade of fuel can causemalfunctions or engine shutdown.

Always change the oil, oil filter and fuel filter at thespecified intervals.

Before re-startingRe-install all guards which have been removed duringservice work, before re-starting the engine. Make surethat there are no tools or other objects left behind onthe engine.

Never start a turbocharged engine without the air filterin place. The rotating compressor turbine in theturbocharger can cause severe injury. There is also arisk that foreign objects are sucked in, causingdamage to the machinery.

Safety Information

6 47704198 09-2016 © AB VOLVO PENTA

Fire and explosionFuel and lubrication oilAll fuel, most lubricants and many chemicals areflammable. Always read and observe the advice onthe packages.

Work on the fuel system must be done with the enginecold. Fuel leakage and spills on hot surfaces orelectrical components can cause fires.

Store oil and fuel-soaked rags and other flammablematerial in a fireproof manner. Oil-soaked rags canself-ignite in certain circumstances.

Spare partsComponents in fuel systems and electrical systemson Volvo Penta engines are designed andmanufactured to minimize the risk of explosions andfire, in accordance with applicable legal requirements.Using spare parts other than those by Volvo Pentaapproved spare parts may cause an explosion or fire.

BatteriesBatteries contain and give off an oxyhydrogen gas,especially during charging. This gas is easily ignitedand highly explosive.

Smoking, open flames or sparks must never occur inor near to batteries or the battery compartment.

Incorrect connection of a battery cable or start cablecan cause a spark which can be enough to make thebattery explode.

Start sprayNever use start spray or similar preparations to aidstarting an engine with air pre-heating (glow plugs /starting heater). They may cause an explosion in theinlet manifold. Danger of personal injury.

Electrical SystemDisconnect the powerBefore any work is done on the electrical system, theengine must be stopped and the power switched offat the main switch(es). Any external power supply forengine heaters, battery chargers or other auxiliaryequipment connected to the engine must bedisconnected.

Electric weldingRemove the positive and negative cables from thebatteries. Then disconnect all cables connected to thealternator. Disconnect both connectors from theengine control module.

Always connect the welder ground clamp to thecomponent to be welded, and as close as possible tothe weld site. The clamp must never be connected tothe engine or in such a way that current can passthrough a bearing.When welding is completed: Always connect thecables to the alternator and engine control unitconnector before reconnecting the battery cables.

BatteriesBatteries contain a highly corrosive electrolyte.Protect your eyes, skin and clothes during chargingand other handling of batteries. Always use protectivegoggles and gloves.

If acid comes into contact with your skin, wash at oncewith soap and a lot of water.If you get battery acid in your eyes, flush at once witha lot of cold water, and get medical assistance atonce.

Safety Information

47704198 09-2016 © AB VOLVO PENTA 7

IntroductionCheck that you heave received the correct Operator’s Manual before you read on. If not, contact your Volvo Pentadealer.

This Operator's Manual contains the information required for the correct, safe operation and maintenance of yourVolvo Penta engine. Read the Operator’s manual carefully and learn to handle the engine and other equipmentin a safe manner before you start the engine.

For the warranty to be valid, the engine must not be used for anything other than it is certified for, it is the operatorsresponsibility to ensure that this is followed.

The Operator’s Manual describes the engine and equipment sold by Volvo Penta. The illustrations in this bookmay cover several product types, which means that there may be slight differences between the illustrations andthe purchased product. This does, however, not affect the validity of the information and/or instructions in themanual. Volvo Penta reserves the right to make alterations to specifications, design features, and illustrationswithout prior notice.

WarrantyYour new Volvo Penta industrial engine is covered bya limited warranty, under the conditions compiled inthe Warranty Information.Note that AB Volvo Penta's liability is limited asspecified in the Warranty Information and EmissionControl System Warranty Statement; read it carefully,as soon as possible after delivery. It containsimportant information about such things as serviceintervals and maintenance that the owner must beaware of, check and perform, otherwise AB VolvoPenta may deny its warranty obligations in part or infull.Contact your Volvo Penta dealer if you have notreceived your Warranty Information or ServiceBook.

Maintenance and replacement partsVolvo Penta engines are designed for maximumreliability and long life. They are not only built towithstand a demanding environment, but also to havethe smallest possible environmental impact. Thesequalities will be maintained through regular servicingand the use of spare parts that comply with thespecification for Volvo Penta approved spare parts.If reliable and purpose-built parts are not used, yoursafety, health, and the machine's function may becompromised.Volvo Penta has a world-wide network of authorizeddealers. They are Volvo Penta product specialists,and have the accessories, genuine parts, testequipment and special tools needed for high qualityservice and repair work.Always observe the maintenance intervals in themanual, and remember to note the engine/transmission identification number when youorder service and spare parts.

Breaking inThe engine must be broken in during its first 10operating hours, as follows:Run the engine in normal operations. However, fullload may not be applied other than for short periods.Never run the engine for long stretches at constantspeeds during this period.Higher oil consumption is normal during the first100-200 hours of operation. For this reason, checkthe oil level more frequently than the normalrecommendation.When a disengageable clutch is installed, it should bechecked more carefully during the first days.Adjustments may be necessary to compensatebedding-in of the friction plates.

Fuel and oilsOnly use fuel and oils of the grades recommended inthe Operator's Manual. Other grades may causeoperational malfunctions, increased fuel consumptionand over time even shorten the life of the engine.Always change the oil, oil filter and fuel filter at thespecified intervals.AB Volvo Penta may deny its warranty obligations inpart or in full if non recommended grades has beenused.

CoolantFuture warranty claims related to engine andaccessories may be denied if an unsuitable coolanthas been used, or if the instructions for coolantmixture have not been followed.

8 47704198 09-2016 © AB VOLVO PENTA

Environmental careAll of us like to live in a clean, healthy environment,where we can breathe clean air, see healthy trees,have clean water in lakes and seas, and enjoysunshine without fearing for our health. Unfortunately,this cannot be taken for granted these days, but it issomething we all must work to achieve.

Volvo Penta has special responsibility as an enginemanufacturer, and for this reason environmental careis a natural cornerstone of our product development.Volvo Penta currently has a broad engine program inwhich great advances have been made in reducingexhaust emissions, fuel consumption and enginenoise etc.We hope that you will be keen to preserve thesequalities. Always follow the directions in theOperator's Manual regarding fuel grades, operationand maintenance to avoid unnecessaryenvironmental impact. Contact your Volvo Pentadealer if you notice any changes such as increasedfuel consumption or increased exhaust smoke.

Remember always to hand in environmentallyhazardous waste such as drained oil, coolant, oldbatteries, etc. for treatment at a recycling facility.

Our united efforts can make a valuable contribution tothe environment.

Certified EnginesIf you own an emission-certified engine used in anarea where exhaust emissions are regulated bylaw, this places special demands on the care andmaintenance you provide your engine.

NOTICE! Neglects or failure to follow the points listedhere may invalidate the engine emission certificate.This means AB Volvo Penta can no longer guaranteeengine conformity with the certified model. VolvoPenta is not responsible for damages or costs arisingas a result of this.

• Certification means that an engine type hasbeen checked and approved by the relevantauthority. The engine manufacturer guaranteesthat all engines of the same type are equivalentto the certified engine.

• It is the responsibility of the operator that nodeliberate misuse of the engine takes place.Especially regarding the EGR andaftertreatment system, if engine is equippedwith these functions.

• Volvo Penta maintenance and service intervalsmust be complied with.

• Any case of malfunction must be rectifiedwithout delay.

• Volvo Penta strongly recommened use VolvoPenta genuine parts or parts with the samequality as Volvo Penta genuine parts.

• The engine must not be converted or modified,except with accessories and service kits thatVolvo Penta has developed for the engine.

• No installation changes to the exhaust pipe andengine air inlet ducts may be made.

• No warranty seals (where present on theproduct) may be broken by unauthorizedpersons.

• The general instructions in the Operator'sManual concerning operation, service andmaintenance apply.

Introduction

47704198 09-2016 © AB VOLVO PENTA 9

Emission Aftertreatment SystemAdBlue®/DEF solutionAdBlue®/DEF solution(1) is mandatory for theequipment/vehicle to comply with emission directivecertification.

When adding AdBlue®/DEF, the solution must fulfillISO22241 standards. If the solution used don’t fulfillthe ISO standard, any warranty claims will be rejected.

Using an engine that does not use AdBlue®/DEFsolution, or the use of low quality solution, where suchis required to reduce air pollution is a punishableoffense. A consequence of such a failure may entailinvalidation of conditions and warranties provided inthe country where the engine is used.

Filling should take place between scheduled serviceintervals. The consumption of AdBlue/DEF solution isa percentage of the fuel consumption and is varyingdepending on the operating conditions.

If the exhaust gas control system does not workcorrectly the operator will be informed by a faultindication.

1. AdBlue® = Registered trademark of the Verband derAutomobilindustrie e.V. (VDA ).

Introduction

10 47704198 09-2016 © AB VOLVO PENTA

Volvo Penta Dealer NetworkThe Volvo Penta global network of authorized dealersis at your service. We strongly recommend that youtake your product to an authorized Volvo Penta dealerfor service and repair. They are specialists in VolvoPenta products and have the accessories, genuineVolvo Penta parts, the special tools and the latestservice information for high quality service and repairwork.

Dealer Locator ServicesLocate the nearest Volvo Penta dealer through ourdealer locator on www.volvopenta.com or downloadthe dealer locator app to your smartphone.

Volvo Penta Action ServiceOur global dealer network, your first line of contact, isbacked up by Volvo Penta Action Service, a phonebased breakdown and support service providingassistance 24 hours a day, every day of the year.

How it worksA dedicated operator will support you all the waythrough your case and keep you updated on status andprogress.Whenever on-site assistance or technical support isneeded, the operator will put you in contact with theclosest Volvo Penta dealer that can support yourproduct.

Phone numbersFind your Volvo Penta Action Service phone numberand more information on www.volvopenta.com.

Introduction

47704198 09-2016 © AB VOLVO PENTA 11

Presentation

EnginesThis Operator's Manual refers to TAD560VE,TAD561VE, TAD761VE, TAD762VE, TAD763VE,TAD764VE and TAD765VE industrial engines.

These engines are in-line, direct injected 4-cylinderand 6-cylinder diesel engines. The engines areequipped with common rail fuel injection systems,electronically controlled fuel management (EMS 2),turbochargers, thermostatically controlled coolingsystems and electronic speed control.

The engines are fitted with SCR systems (SelectiveCatalytic Reduction) in order to reduce exhaustemissions.

TAD560-61VE

TAD761-65VE

P0015986

12 47704198 09-2016 © AB VOLVO PENTA

EMS (Engine ManagementSystem)

EMS (Engine Management System) is an electronic system with CAN communication (Controller Area Network)for diesel engine control. The system has been developed by Volvo Penta and includes fuel control and diagnosticfunction.

Diagnostic functionThe purpose of the diagnostic function is to detect andlocate any malfunctions in the EMS system, to protectthe engine and to ensure operation in the event ofserious malfunction.If a malfunction is detected, it is announced bywarning lamps, a flashing diagnostic lamp or in plainlanguage on the instrument panel, depending on theequipment used. If a fault code is provided as aflashing code or in plain language, it is used forguidance in any fault tracing. Fault codes can also beread by Volvo's Vodia tool at authorized Volvo Pentaworkshops.If there is a serious malfunction, the engine will beshut down altogether, or the control unit will reduceengine power (depending on the application). Onceagain, a fault code is set for guidance in any faulttracing.

Input signalsThe control unit receives input signals about engineoperating conditions etc. from the followingcomponents:

- Coolant temperature sensor

- Charge air pressure and charge air temperaturesensor

- Position sensor, camshaft

- Speed sensor, flywheel

- Coolant level sensor

- Oil pressure sensor

- Fuel pressure sensor

- Water-in-fuel indicator

- Common rail fuel pressure

- Ambient temperature

- External stop input

- Throttle position sensor

- NOx sensor

Fuel controlThe engine fuel requirement is analyzed up to 100times per second. The amount of fuel injected into theengine and the injection advance are fullyelectronically controlled via fuel valves in the unitinjectors.This means that the engine always receives thecorrect volume of fuel in all operating conditions,which provides lower fuel consumption, minimalexhaust emissions, etc.

Output signalsThe control module uses input signals to control thefollowing components:

- Unit injectors

- Start motor

- Main relay

- Pre-heat relay

- MPROP, high pressure fuel pump

- Temperature sensor, AdBlue/DEF solution

- Throttle actuator

- NOx sensor

Information from the sensors provides exactinformation about current operational conditions andallows the processor in the control unit to calculate thecorrect fuel injection volume and timing, check enginestatus, etc.

Presentation

47704198 09-2016 © AB VOLVO PENTA 13

EATS (Exhaust AftertreatmentSystem)SCR technology (Selective Catalytic Reduction) isused to reduce emissions of oxides of nitrogen. Asensor measures NOx levels in the exhaust.

SCR technology treats the exhaust before it passesthrough the catalytic converter by injectingAdBlue/DEF solution into the exhaust stream.

AdBlue/DEF solution consists of de-ionized watermixed with 32.5% urea (the solution must fulfill ISOstandard 22241). The urea is decomposed intoammonia which reacts with NOx to form harmlessnitrogen and water vapor, which occur naturally in ourenvironment.The solution is a transparent, clear liquid with a weakodor of ammonia. The solution is neither flammable norharmful during normal handling. It is howeverextremely corrosive toward metals, especially copperand aluminum.

In order to achieve the most efficient combustionpossible, the engine control unit calculates theoptimum amount of AdBlue/DEF solution that must beinjected in relation to engine load and engine rpm.

SCR system monitoringIf not all of the components in the SCR system areworking as they should, or if the quality of the AdBlue/DEF solution does not fulfill set standards, maximumengine torque will be reduced and a fault code storedin the control unit; for further information refer toDiagnostic Function and Fault Code Register.The reduction is activated automatically whenconditions change.

StoppingWould it remain AdBlue/DEF solution in the hoseswhen it freezes, the whole system could be damaged.To avoid this, and spillages of AdBlube / DEF-solutionthe system is equipped with an automatic drainage sothat the hoses, pump and urea injector is emptied andthe AdBlue/DEF solution goes back to the tank whenthe engine is turned off.

IMPORTANT!Automatic drainage only works when the engine isstopped using the stop button, but not if only the enginepower supply is disconnected.If the system is not drained properly, AdBlue/DEFsolution may squirt out if the hoses are removed, or itcan form ice spuds in the hoses.

EATS (Exhaust Aftertreatment System) is used toreduce emissions. In the SCR-system (SelectiveCatalytic Reduction) the exhaust gases are treatedthrough the addition of AdBlue®/DEF solution beforethey pass through the catalytic converter. Sensors

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measure nitrogen oxide (NOx) levels in the exhaustgases.

The engine control unit calculates the optimum amountof solution to be added in relation to engine load andengine speed, to achieve conversion of the nitrogenoxides that is as efficient as possible.

AdBlue®/DEFThe solution that is added to the exhaust gases is aclear, transparent liquid with a faint odor of ammonia;it consists of de-ionized water mixed with 32.5% urea(the solution must meet ISO 22241 standards). Theurea in the exhaust is broken down into ammoniawhich reacts with NOx to form harmless nitrogen andwater vapor, which occur naturally in our surroundings.

The solution is not flammable or harmful to health withnormal use; it is however very corrosive to metals,especially copper and aluminum.

IMPORTANT:The use of solution that do not fulfill the ISO standardis a punishable offense.Any warranty claims will be rejected.

NOTICE! The urea solution has different names indifferent markets, e.g. DEF or AdBlue®. The solutionis designated either AdBlue or AdBlue/DEF in displaymessages.

MonitoringThe system is monitored to ensure that all systemcomponents are working as they should, that thequality of the AdBlue®/DEF solution fulfills setstandards and that the tank level is not too low. Shouldthe system detect deviations, the maximum enginetorque and engine speed will be reduced and a faultcode stored in the control unit. For further informationrefer to Fault Handling, page 48.

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Shut-downShould any AdBlue®/DEF solution remain in the hosesin freezing weather, the entire system can bedamaged. To avoid this and any solution spillage, thesystem is equipped with automatic drainage when theengine is switched off so that hoses, the pump andinjector are emptied and the solution runs back to thetank.

NOTICE! The automatic drainage only works when theengine is stopped using the ignition switch or the stopbutton on the instrument panel (depending onapplication), not if only the engine power supply isdisconnected. If the system is not drained properly,solution may squirt out if the hoses are disconnected.

CAUTION!Wait at least two minutes after the engine has beenturned off before removing the urea solution hoses sothat automatic drainage and depressurization of theEATS system can take place.

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Major Components

1 Level and temperature sensor

2 Heater valve

3 Silencer with integral SCR catalytic converter

4 Urea tank

5 Urea pump

6 NOx sensor

7 Injector unit

8 Flexible hose

9 Pre-catalytic converter

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Principle solution

The SCR system consists of:

1 Urea tank

2 Pump unit

3 Injector unit

4 Silencer (with integral SCR catalytic converter)

5 SCR catalytic converter

6 Pre-catalytic converter

The urea solution is injected into the exhaust in sprayform by the injector unit before the SCR catalyticconverter.

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TankIMPORTANT:

Dirt/dust, oil, greases, detergents and any chemicalsand natural products must be prevented from enteringthe Adblue/DEF tank.The system will be damaged if dust or dirt enters thetank clogging the filters in the dosing system.Keep the tank clean at all times.

The AdBlue®/DEF-solution is stored in a separatetank.Tanks are made of plastic and are available in differentshapes and sizes.

There is a fitting in the tank that comprises a heatingcoil (1), a float (2) and a strainer (3) on the suction lineto prevent any particles from circulating through thesystem and causing disruptions.The strainer must be checked and cleaned asnecessary.

There is a drain plug (4) on the bottom of the tank sothat the solution can be emptied when necessary, e.g.for cleaning.

The tank is fitted with a breather to equalize pressurechanges.

Tank level

AdBlue®/DEF solution consumption varies duringoperations. The level in the tank is shown on the gaugeas a percentage of the total tank volume.

When the level in the tank falls below the limit, the levelsensor in the tank transmits a signal that closes theinjection valve. A fault code is set in the engine controlunit, a warning lamp lights up and a fault message isshown on the control panel. If AdBlue®/DEF solution isnot added, injection into the exhaust pipe will ceaseand engine rpm and torque will be limited. WhenAdBlue®/DEF is added the fault message is canceledand the engine is once again able to deliver full power.Refer to Fault Handling, page 48 for furtherinformation.

Should the AdBlue®/DEF tank become empty duringoperations this will not lead to damage to the engine or

Example of the location of an AdBlue®/DEF tank.

DCU

DU

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the EATS system, as the remaining solution iscirculating and cooling the system. However,emissions from the engine will increase as the injectionvalve is closed and no exhaust aftertreatment will takeplace.

HeatingBecause AdBlue®/DEF solution freezes at around -11°C (12.2°F) the tank is equipped with a heating coil thatuses engine coolant. A solenoid valve controls the flowof coolant. The hoses between the tank and the pumpare electrically heated and the hose connections areequipped with extra insulation.

NOTICE! Hoses must be handled carefully and nottwisted or bent excessively in order to avoid damagingthe heating system.

Because AdBlue®/DEF solution freezes at around -11°C (12.2°F) the tank is equipped with a heating coil thatuses engine coolant. A solenoid valve controls the flowof coolant. The hoses between the tank and the pumpare electrically heated and the hose connections areequipped with extra insulation.

There is a temperature sensor in the tank that transmitsa signal to the control unit so that the pump cannot startuntil the AdBlue®/DEF solution is fluid. The standardsystem can handle thawing from -40 °C (-40°F). Thesystem is emptied at shut down in order to preventexpansion damage due to freezing. NOTE:

NOTICE! Hoses must be handled carefully and nottwisted or bent excessively in order to avoid damagingthe heating system.

StorageTo prevent breakdown and evaporation during long-term storage, AdBlue®/DEF solution may not be storedat temperatures higher than 25 °C (77 °F) or in directsunlight. Remember that the solution expands uponfreezing and to leave room for expansion in the tankwhen storing in spaces where there is a risk of freezing.

P0011694

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Operation WARNING!

In the case of any contact with eyes or skin the affectedarea must be thoroughly rinsed with lukewarm water.If you inhale any fumes, make sure you breathe freshair.

CAUTION!Risk of corrosive damage.Contact with the fluid can cause irritation andcorrosion.Wear protective gloves!Change gloves and clothing that have been in contactwith the liquid.

AdBlue®/DEF is not a combustible product. Whenexposed to high temperatures it will convert toammonia and carbon dioxide. However, do not allowthe solution to come into contact with other chemicalsor be mixed with other chemicals.

When handling AdBlue®/DEF solution it is importantthat electrical connectors are connected or well-encapsulated. The solution is corrosive toward certainmetals such as copper and aluminum. Shouldoxidation occur, it cannot be removed.If connectors come into contact with the solution theymust be replaced immediately to prevent the solutionfrom seeping further along the copper wiring.

If the solution is spilled onto the engine, wipe it awayand flush with water. White crystals of concentratedAdBlue®/DEF solution may form in the event of a spill;wash the crystals away using water.

IMPORTANT:AdBlue®/DEF solution spillages may not be washedinto drains.If a spill should occur, the solution must be absorbedusing dry sand or other non-flammable material andhandled according to local and national regulations.

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Cleaning tools and clothes CAUTION!

Gloves must be changed. Take off contaminatedclothes.

CAUTION!Tools that come into contact with the fluid must becleaned.

It is important that tools and clothes are thoroughlycleaned from AdBlue®/DEF solution so that the liquidor crystals are not transferred to other parts and causethem damaged.

Contact with AdBlue®/DEF solution

• skin contact — flush with copious amounts of waterand remove contaminated clothing.

• eye contact — flush thoroughly for several minutes;contact physician as necessary.

• inhalation — breathe fresh air and contactphysician as necessary.

p0013225

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Instruments and Controls

Display Control UnitThe DCU control panel is available as an optionalaccessory for the EMS (Engine Management System)electronic control system.The DCU is a digital instrument panel whichcommunicates with the engine control unit. The DCUhas several functions, such as engine control,monitoring, diagnostics, and parameter setting.

The menus in the DCU system can be used to check,and in some cases to set, a number of differentfunctions in the EMS system.

NOTICE! Settings and what engine data that appearsin the display may vary depending on installation andengine model.

NOTICE! The menus and illustrations shown here arethe English version. The language can be changed,however; refer to the Setup menu.

1 2 3 4 5 6

7

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StartWhen the DCU panel is started, the “Engine Data” menu is displayed; press “ESC” to come to the main menu.

1 LED display 6 ON/OFF. Starts and stops the system2 START. Starts the engine 7 Scroll downwards in menus3 SPEED - . Reduces engine rpm 8 SEL. Selects in menus4 SPEED +. Increases engine rpm 9 Scroll upwards in menus5 STOP. Stops the engine 10 ESC. Return to previous menu selection

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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 9buttons on the display. Press the SEL button 8 to makea selection. Refer to the illustration on the previouspage.

NOTICE! The Setup menu can be used to select thelanguage that you want to use on the display.

Main menu

• Engine data, current engine data

• Preheat, manual activation of pre-heating. Must beactivated with temperatures below 0°C (32°F)

• Governor mode, activation of droop

• Diagnostics, shows fault codes as text

• Trip reset, resets trip data

• Setup, parameter setting

• Information, shows the currently applicable hard/software, data sets and engine identification for theengine and DCU data

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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Preheatmanual activation of pre-heating. When it is activated,the EMS system senses at start-up if pre-heating isneeded. For automatic pre-heating, refer to the Setup /Preheat on ignition menu.

NOTICE! Must be activated with temperatures below0°C (32°F).

The pre-heating time is adjusted to suit the enginetemperature, and can last for up to 50 seconds bothbefore and after starting. Refer also to Startingprocedure EMS 2.

• Press SEL, the text Preheat requested will beshown

• The display automatically returns to the EngineData menu.

Governor modeactivates/shuts off droop. To set the droop level, referto the Setup / Governor gradient or Governor droopmenu.

• Select Isochronous mode or Droop mode with theSEL button.

Diagnosticsshows the error list containing the 10 latest active andinactive faults. The fault codes are shown as text onthe display.

• Scroll through the fault list with the arrow keys.

Trip Data resetresets trip data, such as fuel consumption.

• Press the SEL button to reset trip data


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Setupparameter setting in the engine's control systems.Different menus appear under Customer parameter,depending on whether Versatile or Gen set has beenselected from Set application. See below.

The parameters that can be set/selected (choice ismade with the SEL button) are:

• Set application, setting Versatile or Gen set.Depending on the selection made here, differentmenus will appear under Customer parameter.

• Unit, setting of units (metric or US imperial).

• Language, setting the language used on thedisplay. Choose between English, French, Germanand Spanish.

• Stop energized to, setting of external stop input.Activated by Stop or Run.Stop: The stop input must be connected to voltageto stop the engine.Run: The stop input must be connected to voltageto run the engine.

• Customer parameter, setting alarm limits. Refer toCustomer parameter / Versatile and Customerparameter / Gen set.

• Throttle input setting, setting of engine-speedcontrol and voltage limits. Refer to Throttle inputsetting.

• Display setting, setting the display. refer to Displaysetting.

Customer parameter / Versatile

• Idle engine speed - setting idle speed.

• Preheat on ignition - activation of automatic pre-heating. The engine control system senses if pre-heating is needed and activates it directly at switch-on.

• Governor gradient (Nm/rpm) - setting of drooplevel, when activated. For activation, refer toGovernor droop in the main menu.

• Oil temp warning limit (°C) - setting alarm limit foroil temperature.

• Coolant temp warning limit (°C) - setting alarmlimit for coolant temperature.


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Customer parameter / Gen set

• Primary engine speed - selection of engine rpm,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 at switch-on.

• Governor droop (%) - setting of droop level, whenactivated. For activation, refer to “Governor droop”in the main menu.

• Overspeed limit (%) - setting of limit for overspeedalarm, % of set engine rpm.

• Overspeed shutdown - activation of engine shut-down with overspeed alarm. Refer to “Overspeedlimit” to activate the alarm limit for the excess rpmalarm.

• Oil temp warning limit (°C) - setting alarm limit foroil temperature.

• Coolant temp limit (°C) - setting alarm limit forcoolant temperature.

Throttle input settingrpm control setting (throttle operation).

• Set throttle mode - OFF - engine rpm is controlledvia the DCU panel.ext throttle input - engine speed is controlled with apotentiometer (accelerator).ext voltage input - engine rpm is controlled by anexternal unit.

• Set idle voltage (V) - idle voltage level setting.

• Set max voltage (V) - full throttle voltage levelsetting.


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Display settingsettings for the display. Adjustment is made with the 7and 9 buttons; see DCU panel illustration.

• Set contrast (%) - contrast setting.

• Set backlight time (sec) - time setting (in seconds)for display backlighting on, lighting is then shut off ifthe panel is not used.

• Set backlight brightness - display backlightingbrightness setting.

Informationshows the data for the engine and DCU.

• Engine hardware Id - engine control unit partnumber.

• Engine software Id - engine control unit softwarepart number.

• Engine dataset1 Id - engine data set 1 part number.

• Engine dataset2 Id - engine data set 2 part number.

• Vehicle Id - chassis number.

• DCU hardware Id - DCU part number.

• DCU software Id - DCU software part number.

• DCU dataset1 Id - DCU data set 1 part number.

• DCU dataset2 Id - DCU data set 2 part number.


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DU (Display Unit)The DU is an computerized instrument panel whichshows engine working values on an LCD screen. In thedisplay it is possible to show multiple windows withdifferent information, i. g. engine rpm, coolanttemperature, fuel consumption and fault messages.

At start up, the display performs a self-test. If anconstant signal is heard, the system has discovered amalfunction. The display will work but may act in anunexpected way.

The DU is connected between the engine control unitand the CIU or DCU.

Display modesPress any of button 1–4 to view the function menu forthe buttons, apperaring in the lower part of the display.To leave the menu, wait a few seconds or press button5 (EXIT).

1 Engine

2 Multi

3 Trip

4 Graph

5 Exit

ContrastIn the display modes Engine, Trip and Graph, it ispossible to adjust the contrast.Press button 5 outside the menu and then + (button 4)or – (button 3) to adjust the contrast.

P0002061


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EngineRpm and coolant temperature is shown in the upperpart of the display. In the lower part it will show tripcomputer and a fuel level indicator, if these function areinstalled.

MultiIn the multi mode, button 2, the information can beshown in four windows,analogue or digital. The displaytoggles between the two when button 2 is pressedrepeatedly.By pressing button 5, the right arrow, you choose whatinformation to be shown in the different windows.Press repeatedly on the button that correspond to thewindow, until desired information is shown.

TripTo display the trip computer press button 3, Trip

Trip Fuel, since last reset

Fuel Rate, fuel consumption

Trip hours, since last reset

Engine hours, total amount of operating hours

Reset by pressing button 3 for three seconds until abeep is heard.

GraphThe information is shown as graphs. Press button 4repeatedly to choose what information will be shown.The time interval is set in the Configuration menu.If the connection is broken there will be a straight linein the display.


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Configuration menuPress button 5 for three seconds to enter theConfiguration menu. Navigate with the up and downarrows, select with the right arrow.

Units

- PRESSURE; kPa, PSI

- VOLUME; LITRE, GAL, Imperial GAL.Fuel rate is adjusted according to volume unit, L/H,GAL/H, IGAL/H.

- TEMPERATURE; °C, °F

Alarm Status

List of active alarms, refer to Reading fault codes viathe DU (Display Unit)


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Settings

- LANGUAGE; setting of what language is to be usedin the display.

- BLEEP; On/Off, setting if pressing the instrumentbuttons will be followed by a beep or not.

- DISPLAY; setting of ENGINE RPM gaugesRPM ENGINE, 2500–9000 RPM, in steps of 500RPMGRAPH RANGE, 2 minutes– 8 hours in thefollowing steps,2MINS, 10MINS, 30MINS, 60MINS, 2HRS, 4HRS,8HRS

SYSTEM

- DEMO, switches the DEMO mode ON/OFF.

- RESTORE DEAFAULTS, reset all configuration todefault values.

- COM VIEWER, displays latest message oncommunication ports

- PROG TX, transfers content of the application onFlash memory to other CAN units on the same CANbus.

- ABOUT, displaysID NO – display serial numberEEPROM – number of write on EEPROMVERS – software version numberCHK – Flash memory checksumPART No – Volvo software part numberSOURCE – source of received dataLABLE – Allocated Label on the same bus.


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CIU (Control Interface Unit)The CIU is a "translator" between the control unit(EMS) and the customer's own control panel. The CIUhas two serial communication links, one fast and oneslow.

The fast one is a so-called CAN link. All data related toinstruments, indication lamps, connectors andpotentiometers is controlled by this link.

The slow link manages diagnostic information forflashing codes etc.

Easy Link InstrumentsThe following Easy Link instruments are available:

- Tachometer / hours counter (fault codes are alsodisplayed on the tachometer display when thediagnostic button is pressed)

- Coolant temperature

- Oil pressure

- Oil temperature

- Battery voltage

- Alarm panel

- Turbo pressure

P0002060


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Optional

Stop/StartThe automatic start/stop function stops the enginewhen the vehicle stops temporarily and then restarts itautomatically. By avoiding engine idling, fuelconsumption and CO2 emissions are reduced.

The engine needs to reach operating temperature forthe function to be activated, and the battery must havea charge sufficient to restart the engine. A batterysensor measures battery temperature, which must bebetween 0–55 °C; the temperature in the urea tankmust be above 5 °C.

Activation and autostartThe engine may be auto-stopped max 10 times perhour. If the vehicle is left in auto-stop mode for morethan 4 minutes, the engine system is switched off andmust be restarted via the control panel.The procedure for activating the function and restartingthe engine may differ depending on the application. Inorder to know which option is applicable seedocumentation from the machine manufacture for thecurrent machine.

Option 1

1 Stop the vehicle and put the gear shift lever in theneutral position.

2 Hold down the brake pedal; the engine stops.

3 To restart the engine, press down hard on thebrake pedal.

Option 3


2 Hold down the brake pedal; the engine stops.

3 To restart the engine, press down on the brakepedal.

Option 2


2 Set the park brake; the engine stops.

3 To restart the engine, release the park brake andpress down hard on the brake pedal.

Option 4


2 Set the park brake; the engine stops.

3 To restart the engine, release the park brake andpress down on the brake pedal.

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StartingMake it a habit of giving the engine and engine room a visual check before starting. This will help you to discoverquickly if anything abnormal has happened, or is about to happen.Also check that instruments and warning displays show normal values after you have started the engine.

WARNING!Never use start spray or similar agents to start an engine. This may cause an explosion in the inlet manifold. Riskof personal injury.

Before Starting• Check that the oil level is between the MIN and MAX

marks.For filling refer to Oil level, checking and toppingup.

• Open the fuel valves.

• Check the fuel pre-filter; refer to Drainingcondensate, fuel system, page 62.

• Check that no leakage of oil, fuel or coolant ispresent.

• Check the air filter pressure drop indicator. Refer toMaintenance, page 55.

• Check the coolant level and that the radiator is notblocked externally. Refer to Coolant Level,Checking and Topping Up, page 67 and ChargeAir Cooler, External Cleaning, page 69

WARNING!Do not open the coolant filler cap when the engineis hot, except in emergencies as this could causeserious personal injury. Steam or hot fluid couldspray out.

• Turn the main switch on.

IMPORTANT:Never break the circuit with the main switch whilethe engine is running.Alternator and electronics could be damaged.

• Move the engine speed control to idle, and open thedisengageable clutch/gearbox if installed.

P0002078

MIN KALTCOLD

P0008964

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Starting the Engine

DCU (Display Control Unit)The pre-heating time is adjusted to suit enginetemperature, and may last up to 50 seconds bothbefore and after starting.

The starter motor connection time is maximized to 20seconds. After that, the starter motor circuit is cut for80 seconds to protect the starter motor againstoverheating.

NOTICE! Preheat must be activated when thetemperature is below 0 °C (32 °F)

2 6

79

P0008961

With preheating

1 Press the ON/OFF button (6).

2 Press the SEL button (7) to come to the mainmenu.

3 Navigate to Preheat with the browse button (9).Press the SEL button (7)

4 In the Preheat 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 disappears and then press theSTART button (2).

Without pre-heating

1 Press the ON/OFF button (6).

2 Press the START button (2).

Warm through the engine at idle (1,500/1,800 rpm).

Starting

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Starting in Extreme ColdCertain preparations must be made to enable enginestarting in extreme cold, and in some cases to makestarting possible at all:

• Use a winter grade fuel (of a well-known make) thatis approved for the prevailing temperature. Thisreduces the risk of paraffin wax precipitation in thefuel system. At extremely low temperatures, werecommend the use of a fuel heater.

• Use a synthetic engine oil of a viscosityrecommended for the prevailing temperature toachieve satisfactory lubrication. Refer toViscosity, page 82. Synthetic lubricants are ableto handle a wider temperature range than mineral-based lubricants.

• Pre-heat the coolant with a separately-installedelectric engine heater. In extreme cases, a diesel-fired engine heater may be necessary. Ask yourVolvo Penta dealer for advice.

• Make sure the cooling system is filled with a coolantmixture. Refer to Maintenance, page 66.

• The batteries must be in good condition. Coldweather reduces battery capacity. Increased batterycapacity may be necessary.

Starting

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Never Use Start Spray WARNING!

Never use start spray or similar agents to start anengine. This may cause an explosion in the inletmanifold. Risk of personal injury.

Starting Using Auxiliary Batteries WARNING!

Explosion hazard. Batteries contain and give off anexplosive gas which is highly flammable and explosive.A short circuit, open flame or spark could cause aviolent explosion. Ventilate well.

1 Check that the auxiliary batteries are connected(series or parallel) so that the rated voltagecorresponds to the engine system voltage.

2 First connect the red (+) jumper cable to theauxiliary battery, then to the flat battery. Thenconnect the black (-) jumper cable to the auxiliarybattery and to a location that is somewhere awayfrom the discharged battery, e.g. the main switchnegative terminal or the negative terminal on thestarter motor.

3 Start the engine.

WARNING!Do not touch the connections during the startattempt: Risk of arcing.Do not bend over any of the batteries either.

4 Remove the cables in the reverse order.

IMPORTANT:The ordinary cables to the standard batteries must notunder any circumstances be loosened.Potential Consequence of hazardPrecautionary Actions to be taken

P0002080

Starting

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OperationCorrect operating 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 operationat high engine speed.

Reading the InstrumentsCheck all instruments directly after starting, and thenregularly during operation.

NOTICE! On engines in continuous operation, it isrecommended that the lubrication oil level is checkedat least every 24 hours. Refer to Oil level, checking andtopping up.

AlarmsIf the EMS receives abnormal signals from the engine,the control unit generates fault codes and alarms, inthe form of lamps and audible warnings. This is doneby means of CAN signals to the instrument.

More information about fault codes and fault tracingcan be found in the chapter. Fault Handling.

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Maneuvering

Operation at low loadAvoid long-term operation at idle or at low load, sincethis can lead to increased oil consumption andeventually to oil leakage from the exhaust manifold,since oil will seep past the turbocharger seals andaccompany the induction air into the inlet manifold atlow turbo pressure.One consequence of this is carbon build-up on valves,piston crowns, exhaust ports and the exhaust turbine.

At low loads, the combustion temperature maybecome so low that complete combustion cannot beensured, resulting in possible fuel dilution of lubricatingoil and eventually leakage from the exhaust manifold.

If the following points are done as a complement tonormal 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, the duration of this operation should belimited to 5 minutes.

• Run the engine at full load for about 4 hours once ayear. In this way carbon deposits in the engine andexhaust system are given the chance to burn up.

Operation

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Engine ShutdownDuring longer breaks in operation, the engine must be warmed up at least once every two weeks. This preventscorrosion in the engine. If you expect the engine to remain unused for two months or more, it must be preserved:Refer to the chapter Storage, page 79.

Before Engine ShutdownLet the engine run for a few minutes without any loadbefore stopping it. This allows engine temperatureequalization and prevents boiling once stopped andalso allows the turbochargers to cool down. Thiscontributes to long, fault-free service life.

Stop the Engine• Disengage the clutch (if possible).

• Press the STOP button (5) / turn the key to S.

• Disengage the clutch (if possible).

• Depress the STOP-button (5).

Auxiliary stop WARNING!

Working with or approaching a running engine is asafety risk. Watch out for rotating components and hotsurfaces.

The auxiliary stop (AUX STOP) is located to the rightof the steering unit.

NOTICE! The auxiliary stop may under nocircumstances be used as the "routine" stop button.

5

P0008963

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After Engine Shutdown

1 Check the engine and engine compartment forleaks.

2 Turn off the main switches before any longstoppage.

3 Carry out maintenance in accordance with theschedule.

For longer breaks in operationDuring longer breaks in operation, it is recommendedthat the engine is warmed up at least once every twoweeks. This prevents corrosion in the engine.If you expect the engine to be unused for two monthsor more, it should be conserved. Refer to the chapterStorage, page 79 .

IMPORTANT:If there is a risk of freezing, the coolant in the coolingsystem must have adequate antifreeze protection.

Refer to the chapter Maintenance, page 66.

IMPORTANT:A poorly-charged battery can freeze and burst

Refer to Battery, Charging.

P0002078

Engine Shutdown

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Fault HandlingDCU (Display Control unit)

1 When a fault is detected the following text isdisplayed:!! ENGINE WARNING !! alternating withPress SEL for information.

2 Reduce engine speed to idle or shut down theengine.

3 Press the SEL button to get to the fault list.The fault list shows:– hours of operation– fault messages– active/non-active faults

4 Look up the fault code in the Fault Code Registerand take the necessary actions.

5 Press ESC to leave the fault list.

NOTICE! To get to the fault list when no fault codesare set, press the SEL button and select Diagnosticsfrom the menu.

DU (Display Unit)

1 If the system detects a fault, a pop-up is shown onthe display. Depending on the severity of the faultthe following text will appearALARM STOP / PRESS ANY KEY orWARNING! / PRESS ANY KEY; a buzzer willsound.

2 Reduce engine speed to idle or shut down theengine.

47704198 09-2016 © AB VOLVO PENTA 43

3 Press the SEL button to get to the fault list. The faultlist shows fault messages and the number of hoursof operation when the fault occurred.

4 Press ACK to acknowledge the fault code. Thedisplay background changes color (and the buzzerstops). The fault must be acknowledged before itcan disappear from the fault list.


6 Press button 4 for at least three seconds to viewSPN and FMI codes.

7 Press EXIT to leave the fault list.

Easy Link Instruments

1 When a malfunction is detected this is reported bythe diagnostic lamp which starts to flash.

2 Press the diagnostics button. The fault code isshown as text in the tachometer display.


4 When the fault has been rectified, the fault codedisappears from the display and the diagnosticslamp goes out.

Fault Handling

44 47704198 09-2016 © AB VOLVO PENTA

Erasing fault codesThe memory of the diagnostic function is reset whenthe power to the engine is disconnected. When thepower is switched on again, the diagnostic function willcheck if there are any malfunctions in the system. If soa new fault codes is registered.

If a malfunction has not been corrected it will beregistered once again and has to be acknowledgedagain. The Volvo Penta diagnostic tool VODIA must beused to erase a fault code.

Fault Handling

47704198 09-2016 © AB VOLVO PENTA 45

Fault TracingA number of symptoms and possible causes of enginemalfunctions are described in the table below. Alwayscontact your Volvo Penta dealer if any problems occurwhich you cannot solve by yourself.

IMPORTANT:Read through the instructions for care andmaintenance in before starting work.

Refer to Safety Information, page 4.

Symptoms and possible causesThe diagnostics button indicator flashes Refer to Diagnostic FunctionEngine cannot be stopped 2, 5Starter motor does not rotate 1, 2, 3, 4, 5, 6, 7, 24Starter motor rotates slowly 1, 2Starter motor rotates normally but engine does notstart

8, 9, 10, 11,

Engine starts but stops again 8, 9, 10, 11, 13Engine does not reach correct operating speed atfull throttle

9, 10, 11, 12, 13, 21, 25, 26

Engine runs unevenly 10, 11High fuel consumption 12, 13, 15, 25Black exhaust smoke 12, 13Blue or white exhaust smoke 15, 22Lubrication oil pressure too low 16Excessive coolant temperature 17, 18, 19, 20Coolant temperature too low 20No charge, or poor charge 2, 23

Fault Handling

46 47704198 09-2016 © AB VOLVO PENTA

1 Discharged batteries

2 Poor contact/open circuit in cables

3 Main switch turned off

4 Main automatic breaker defective

5 Defective ignition switch

6 Defective main relay

7 Defective starter motor/solenoid valve

8 Lack of fuel:– fuel taps closed– fuel tank empty/wrong tank connected

9 Blocked secondary fuel filter/ primary filter (due to contamination, stratification due to low fuel level)

10 Air in the fuel system

11 Water/contaminants in fuel

12 Faulty injector

13 Insufficient air supply to engine:– blocked air filter– air leakage between turbo and inlet manifold– dirty compressor section in turbocharger– defective turbocharger– poor engine bay ventilation

14 Excessive coolant temperature

15 Coolant temperature too low

16 Oil level too low

17 Coolant level too low

18 Air in cooling system

19 Faulty circulation pump

20 Defective thermostat

21 Blocked charge air cooler

22 Oil level too high

23 Alternator drive belt slipping

24 Water entry into engine

25 High back pressure in exhaust system

26 Break in “Pot+” cable to pedal

Fault Handling

47704198 09-2016 © AB VOLVO PENTA 47

EATS Warnings andInducements

DEF Tank LevelTriggers DCU Display Message Level Indicator Amber

WarningLamp

Inducement

>23% Tank Level None None None None<8–23% Tank Level DEF/AdBlue level low None None

<8% Tank Level AdBlue®/DEF level empty(alternately)Engine derate

None Ramped torque reduction1%/minute to fullinducement.Full inducement is 0%available torque > 900 rpm.

<8% Tank Level afterrestart

AdBlue®/DEF level empty(alternately)Severe inducement

None Full inducement from start,0% available torque > 900rpm.

SCR TamperingPossible reasons:1. Disconnected DEF tank level sensor 4. Disconnect DEF pump2. Blocked DEF line or dosing unit 5. Disconnected SCR wiring harness3. Disconnected DEF dosing unit 6. Disconnected NOx Sensor

Fault Handling

48 47704198 09-2016 © AB VOLVO PENTA

Triggers DCU Display Message AmberWarningLamp

Inducement

No Tampering None None NoneTampering Confirmed AdBlue/DEF System Warning

P0002361

Tampering Detected AdBlue/DEF System Warning(alternately)Engine derate

P0002361

Ramped torque reduction 1%/minute to full inducement.Full inducement is 0% availabletorque > 900 rpm.

Tampering InitialDetected after restart

AdBlue/DEF System Warning(alternately)Severe inducement P0002361

Full inducement from start, 0%available torque > 900 rpm.

DEF QualityTriggers DCU Display Message Amber

WarningLamp

Inducement

Good Quality None None NonePoor Quality InitialDetected

AdBlue/DEF System Warning

P0002361

None

Poor Quality InitialDetected

AdBlue/DEF System Warning(alternately)Engine derate P0002361

Ramped torque reduction 1%/minute to full inducement. Fullinducement is 0% available torque> 900 rpm

Poor DEF Quality InitialDetected after restart

AdBlue/DEF System Warning(alternatey)Severe inducement P0002361

Full inducement from restart, 0%available torque > 900 rpm.

Temporary exit fromsevere inducement

AdBlue/DEF System Warning(alternately)Temporary Override of Inducement P0002361

See below, ”Exit conditions for DEFQuality severe inducement”

Exit conditions for DEF Quality severe inducement:First Restart:Allow time to run the quality check function. If poorDEF quality is detected during the first monitoringcycle, then inducement is resumed.Service tool is required to exit at this point.

With Service Tool clearingAllow time to run the quality check function. If poorDEF quality is detected during the first monitoringcycle, then severe inducement is resumed.Inducement ends when quality fault ceases.

Fault Handling

47704198 09-2016 © AB VOLVO PENTA 49

Fault Code RegisterFault codes, SCR-system

SPN PID PPID SID PSID FMIEngine Throttle position 51 51 2, 3, 4, 5, 7,

11, 12, 13,14

Relative Humidity 354 354 3, 5Humidity sensor temperature 442 271 4, 5Air temperature for humidity compensation 442 272 4, 5AdBlue®/DEF internal filter heater 858 82 3, 4, 5AdBlue®/DEF external filter heater 859 107 3, 4, 5Aftertreatment reagent level 1761 278 3, 5, 11, 14,

18Aftertreatment reagent pressure 2061 273 8Aftertreatment reagent levelFilling AdBlue®/DEF solution, page 71

2061 278 13

AdBlue®/DEF ECU voltage 2061 385 14AdBlue®/DEF ECU EEPROM 2061 77 12Aftertreatment reagent temperature in tank 3031 274 0, 1, 4, 5Aftertreatment reagent dosing valve 3051 90 11NOx sensor gas outlet 3226 270 2, 7Aftertreatment reagent quality sensor 3360 123 2, 6, 9, 12,

13AdBlue®/DEF dosage valve 3361 89 3, 4, 5, 7, 10AdBlue®/DEF tank heating valve 3363 75 3, 4, 5AdBlue®/DEF Quality 3364 351 10Engine throttle actuator 3464 7 3, 4, 5, 12AdBlue®/DEF ECU EEPROM 3511 77 3, 4Aftertreatment reagent pressure 3512 273 13AdBlue®/DEF consumption 3522 91 16, 18High NOx level 4090 45 0, 14, 16Too low reagent consumption 4093 41 1, 14, 18Aftertreatment reagent quality 4094 40 1, 14, 18Reagent dosing 4094 42 14AdBlue®/DEF level empty 4096 115 1NOx monitoring failure 4225 46 2, 14Aftertreatment reagent pressure 4334 273 1, 4, 5, 7, 9,

10, 13Regent filter temperatur 4337 275 0, 1, 2, 4, 5AdBlue®/DEF Hose heater no.1 4354 103 3, 4, 5, 14AdBlue®/DEF Hose Heater no.2 4355 84 3, 4, 5, 14AdBlue®/DEF Hose Heater no.3 4356 102 3, 4, 5, 14AdBlue®/DEF Hose Heater no.4 4357 104 3, 4, 5Aftertreatment reagent pump motor speed 4374 87 0, 1, 10Aftertreatment reagent direction valve 4376 105 3, 4, 5, 7NOx monitoring failure 5246 46 0, 15, 16

50 47704198 09-2016 © AB VOLVO PENTA

SPN PID PPID SID PSID FMIAftertreatment reagent Dosing system 5394 90 17AdBlue®/DEF ECU main relay 520233 85 3, 4, 5, 6

Fault Code Register

47704198 09-2016 © AB VOLVO PENTA 51

Maintenance ScheduleYour Volvo Penta engine and its equipment are designed for high reliability and long life. The engines are built tohave the smallest possible environmental impact. If given preventive maintenance, according to the maintenanceschedule, these qualities will be retained and unnecessary malfunctions will be avoided. It is the owner'sresponsibility to make sure that the services in the service intervals are performed for the warranty to be valid.NOTICE! For emission related warranty rights see Emission Control System Warranty Statement.

Service IntervalsService intervals are shown below. The service content can be found in the Service Protocol available fordownload at www.volvopenta.com. Navigate to Engine database and enter serial number.

Extended service intervalsThe interval between engine oil changes may be extended in certain circumstances. To determine whether theservice interval may be extended, Volvo Penta's conditions for extended service intervals must be met and an oilanalysis performed. Contact your Volvo Penta dealer for further information.

Where both operational and calendar times are specified, perform the maintenance item at whichever time is thesooner.

Special Interval Service S1 Every 125-600 hours / at least every 12 month(1)(2)

Special Interval Service S2 Oil analysis.

Special Interval Service S3 After the first 500 hours.

Type A service Every 500 hours of operation.Type B service Every 1000 hours of operation.Type C service Every 1500 hours of operation.Type D service Every 2000 hours of operation.Type E service Every 8000 hours of operation.

1) Oil change intervals vary, depending on oil grade and sulfur content of the fuel. Please refer to Oil recommendations.2) Change oil filters every time the oil is changed.

52 47704198 09-2016 © AB VOLVO PENTA

MaintenanceThis chapter describes the most common maintenance items. Refer to Maintenance Schedule for serviceintervals.

NOTICE! Service points which are not described here are recommended to be performed by an authorized VolvoPenta workshop or equally qualified personnel.

CAUTION!Read through the safety advice before starting any work.

WARNING!Care and maintenance work should be done with the engine stopped unless otherwise specified. Stop the enginebefore opening or removing the engine hatch/hood. Make it impossible to start the engine by removing the startkey and cutting the system voltage with the main switches.

When ordering service or spare parts, always specify the engine and transmission identification number. Referto Technical Data, page 87.

47704198 09-2016 © AB VOLVO PENTA 53

Orientation1 Crankcase ventilation

2 Oil filler cap, engine

3 Fuel Filter

4 Common Rail unit, with safety valve and railpressure sensor

5 Oil filter

6 Lifting eyes, (2 pcs)

7 Inlet, after charge-air cooler

8 Coolant outlet, from thermostat housing

9 Fan hub

10 Alternator

11 Drive Belt

12 Drive gear, crankshaft

13 Oil Sump

14 Belt Tensioner

15 Coolant inlet, to engine

16 Oil cooler

17 Coolant Pump

18 Oil dipstick, engine

19 High pressure pumps

20 Intake manifold

21 Valve Cover

22 Air filter indicator

23 Fuel pump

24 Flywheel Housing

25 Starter motor guard

26 Charge air, to cooler

27 Drain plug, oil pan

28 Oil pipe, from turbo

29 Turbo

30 Relay

31 Exhaust Manifold

32 Throttle

Maintenance

54 47704198 09-2016 © AB VOLVO PENTA

Engine, General

General inspectionMake it a habit to give the engine and enginecompartment a visual inspection before starting theengine and after operation once the engine hasstopped. This will help you to discover quickly ifanything abnormal has happened, or is about tohappen.Look especially carefully at oil, fuel and coolantleakage, loose bolts, worn or poorly tensioned drivebelts, loose connections, damaged hoses andelectrical cables. This inspection only takes a fewminutes and can prevent serious malfunctions andexpensive repairs.

WARNING!Accumulations of fuel, oil and grease on the engine orin the engine room constitute a fire hazard and mustbe removed as soon as they are detected.

WARNING!If an oil, fuel or coolant leak is detected, the cause mustbe investigated and the fault rectified before the engineis started.

IMPORTANT:Washing with a power washer: Never aim the water jetat radiators, charge air cooler, seals, rubber hoses orelectrical components.

Maintenance

47704198 09-2016 © AB VOLVO PENTA 55

Air Filter, Change

Removal1 Remove the filter housing cover/end panel.

Remove the air filter.Clean inside the housing.

2 Where necessary, remove the air filter housinginner part and clean it.

Installation3 Replace the air filter housing inner part.

Install a new air filter.

4 Install the filter housing cover/end panel.

P0003118

P0003119

P0003120

P0003121

Maintenance

56 47704198 09-2016 © AB VOLVO PENTA

Charge Air Pipe, Leakage Check

Inspect the condition of the charge air hoses, hoseunions and clamp condition for cracks and otherdamage. Change as necessary.

Maintenance

47704198 09-2016 © AB VOLVO PENTA 57

Drive Belt, Check and ChangeIMPORTANT!Always change a belt which is oily, worn or damaged.Belts which operate in pairs must be changed together.

Inspection should be carried out after operation, whenthe belt is hot. It should be possible to depress the drivebelt about 3-4 mm (0.12–0.16") between the pulleys.The drive belt has an automatic belt tensioner andtherefore does not need to be adjusted.

1 Release the belt tensioner and lock it in place witha drift (1).

2 Remove the belt from the coolant pump (2) first.Install the new belt.Remove the belt tensioner and the drift (1). Checkthat the belts are correctly aligned in their groovesand are correctly tensioned.

P0003350

1

2

P0008974

Maintenance

58 47704198 09-2016 © AB VOLVO PENTA

Lubrication System

Oil change intervals may vary according to thelubrication oil grade, fuel sulfur content and runningconditions. Refer to Oil recommendations.

The oil change interval may under certain conditionsbe increased. To see if the engine complies VolvoPenta oil analysis needs to be performed. Contact yourVolvo Penta dealer for further information.

NOTICE! Oil change intervals must never exceed aperiod of 12 months.

Oil level, checking and topping up WARNING!

Working with or approaching a running engine is asafety risk. Watch out for rotating components and hotsurfaces.

• When checking the oil level the vehicle should standon level ground.

• Only use a recommended grade of oil; refer to Oilrecommendations.

• Make sure that the oil level is between the MIN andMAX marks. Do not fill above the maximum oil level.

P0002089

MAXMINP0019132

Maintenance

47704198 09-2016 © AB VOLVO PENTA 59

Oil filter, ChangeChange the oil filters during each oil change.

WARNING!Hot oil and hot surfaces can cause burns.

Removal

1 Drain the oil according to the instructions inEngine Oil, Change, page 61.

NOTICE! Position a suitable vessel underneaththe filter to avoid oil spillage.

2 Clean around the oil filter.

3 Carefully remove the oil filter cover (1) and filter.

4 Remove the O-ring (2) and filter (3)

5 Let the oil drip off into a collection vessel.

Installation

6 Install a new filter (3) and a new O-ring (2).

7 Install the filter cover (1) and filter.Torque to: 40 Nm (29.5 lbf.ft.)

8 Fill with required volume of oil, see Engine Oil,Change, page 61.

Carry out a function test

• Start the engine.

• Check that there is no oil leakage from the oil filteror drain nipple.

• Turn off the engine.

• Check the oil level after a few minutes.

• Top up with oil as necessary.

Engine Model Spec.No Serial No kw(G)redkw(G)red

rm

Kw(S)red

C

Kw(G) Kw(S)

Kw(W)

MAID IN GERMANY

1/min

7

1

2

3

P0008977

Maintenance

60 47704198 09-2016 © AB VOLVO PENTA

Engine Oil, ChangeAlways follow the recommended oil change intervaland always change the oil filter in connection with oilchanges. On static engines the drain plug must not beremoved. Use an oil drain pump to pump the oil out.

WARNING!Hot oil and hot surfaces can cause burns.

1 Run the engine until warm.

2 Remove the drain plug. Drain the oil.

NOTICE! Collect the old oil and old filters andhand them to a re-cycling station.

3 Install the drain plug with a new gasket.

4 Change the oil filter according to the Oil filter,Change, page 60 instruction.

5 Fill oil to the correct level.

NOTICE! Do not fill above the MAX level.

6 Start the engine and let it idle. Check that the oilpressure is normal.

7 Stop the engine. Check that there is no oilleakage around the filters. Top up with oil asnecessary.

P0008966

Maintenance

47704198 09-2016 © AB VOLVO PENTA 61

Fuel System WARNING!

Fire hazard. When carrying out work on the fuel systemmake sure the engine is cold. A fuel spill onto a hotsurface or an electrical component can cause a fire.Store fuel soaked rags so that they cannot cause fire.

Store fuel-soaked rags so that they cannot cause fire.

IMPORTANT:Always observe the greatest cleanliness duringrefueling and work on the fuel system.Only use the grades of fuel recommended in the fuelspecification.

Draining condensate, fuel system

1 Stop the engine and close the fuel tap.

2 Put a collection vessel under the fuel pre-filter tocollect the condensate and fuel.

3 Open the drain nipple (1) at the bottom of the waterseparator (2).

4 Drain the water contained in the water separatorinto the collection vessel.

NOTICE! Do not drain the water separatorcompletely.

5 Tighten the drain nipple and open the fuel tap.

6 Start the engine and check there is no fuel leakagefrom water separator.

P0002101

1

2

P0019216

Maintenance

62 47704198 09-2016 © AB VOLVO PENTA

Engine Fuel Filter Replacement

Removal

1 Clean around the fuel filter.

2 NOTE! The filter is self-draining (when the fueltank is located under the engine); wait a coupleof seconds before removing the filter cover andfilter.

If the fuel tank has a "higher" location:

3 Close the cock on the return line to the tank. Placea suitable vessel underneath the filter.Disconnect the quick connector on the return line.

4 Remove the filter cover (1).

5 Remove the O-ring (2) and filter (3).

Installation

6 Install a new filter (3) and a new O-ring (2).

7 Install the filter cover (1) and filter.

If the fuel tank has a "higher" location:

8 Reconnect the quick connector on the return line.Open the cock on the return line and remove thecollection vessel.

9 Purge the fuel system according to the method,Fuel system, bleeding.

10 Warm up the engine and perform a function checkin respect of any leakages.

1

3

2

P0008973

Maintenance

47704198 09-2016 © AB VOLVO PENTA 63

Fuel Pre-filter, Change

Removal1 Clean around the pre-filter and the water

separator.Open the drain nipple (1) in the base of the waterseparator.

2 Tighten the drain nipple (1).Remove the lower part of the water separator (2).Remove the pre-filter (3); use a filter wrench.

3 Clean the mating surfaces.

Installation4 Grease the gasket surfaces.

Fit the new pre-filter (3).Tighten according to the instructions on the filter.

5 Install the lower part of the water separator (2).

NOTICE! Use a new seal ring.

6 Open the fuel taps and purge the fuel system;refer to Fuel system, bleeding.

7 Start the engine and check for leaks.

3

2

1

P0008970

2

3

P0008971

Maintenance

64 47704198 09-2016 © AB VOLVO PENTA

Fuel system, bleeding1 Open the hand pump (1), by pressing it in and

turning it counter-clockwise.

2 Purge the fuel system by pumping at least 250strokes on the hand pump.Pump rapidly, to maintain pressure in the pump.

NOTICE! Purging is not complete whileresistance is felt in the pump.

3 Close the hand pump (1) by pressing it in andturning it clockwise.

4 Start the engine and let it idle for at least 5minutes, before speed is increased.

1

P0003304

Maintenance

47704198 09-2016 © AB VOLVO PENTA 65

Cooling SystemThe cooling system ensures that the engine operatesat the correct temperature. It is a closed system thatshould always be filled with a coolant mixture.

IMPORTANT:Coolant of a suitable chemical composition must beused all year round to protect the engine againstinternal corrosion, cavitation and frost bursting.This even applies when there is no risk for frostdamage, to make sure the engine always has acomplete corrosion protection.

Therefore, the use of anti-corrosion agents alone, orwater alone as a coolant, is not permitted in VolvoPenta engines.

The coolant must be based on Organic AcidTechnology (OAT). Using an improper coolant ormixing with another coolant will rapidly reduce theperformance and lifetime of the engine. Materialincompatibility can lead to leakages, which - in theworst case - can cause engine breakdown.

Volvo Penta strongly recommend the use of our owncoolants, ”Volvo Penta Coolant VCS Ready Mixed” orthe concentrate ”Volvo Penta Coolant VCS”, whichensure the protection of the cooling systemcomponents from corrosion, ageing, swelling andcracking, thereby ensuring optimal engine lifetime.

Over time the corrosion protection additives becomeless effective, and consequently the coolant must bechanged at regular intervals to maintain sufficientprotection of the engine. The latest Service Protocolthat specifies service intervals can be found atvolvopenta.com.

Coolant, MixingIt is extremely important that the system is filled withthe correct coolant concentration; refer to Coolant,Mixing.The coolant should be mixed with distilled, deionizedwater. For Volvo Penta specified water requirements;refer to Water Quality, page 85.

NOTICE! If water quality can not be guaranteed, useready mixed coolant.

coolant vcs ready mixed

P0013077

Maintenance

66 47704198 09-2016 © AB VOLVO PENTA

Coolant Level, Checking andTopping Up

WARNING!Do not open the coolant filler cap when the engine ishot, except in emergencies as this could cause seriouspersonal injury. Steam or hot fluid could spray out.

Check the coolant level daily before starting. Top upwith coolant as necessary.

NOTICE! The coolant level must be higher than theMIN marking.

IMPORTANT:Only use coolant recommended by Volvo Penta.Top up with the same type of coolant as already usedin the system.Different types of coolant must not be mixed.

Filling a completely empty systemFilling must be done with the engine stopped. Fill upslowly, to allow the air to flow out. The system is ventedautomatically.

Fill up with coolant to the correct level. Do not startthe engine until the system is vented andcompletely filled.

Start the engine and warm it up for about 20 minutesuntil the thermostats are open. Open any venting tapsa short while after starting, to allow trapped air toescape. Check the coolant level and top up asnecessary.

NOTICE! If a heating unit is connected to the enginecooling system, the heat control valve must be openedand the installation vented during filling.

MIN KALTCOLD

P0008964

Maintenance

47704198 09-2016 © AB VOLVO PENTA 67

Coolant, Draining

Before draining, stop the engine and unscrew thefiller cap.

WARNING!Do not open the coolant filler cap when the engine ishot, except in emergencies as this could cause seriouspersonal injury. Steam or hot fluid could spray out.

WARNING!All coolant is hazardous and harmful to theenvironment. Do not consume. Coolant is flammable.

There is a drain plug (1) in the engine block, and a drainnipple (2) under the radiator for draining coolant.

1 Put a suitable vessel underneath the drain plug(1) and undo the plug.Then put a suitable vessel underneath theradiator and remove the protective cap from drainnipple (2). Connect a suitable hose and drain offthe coolant.

2 Let the coolant run out.

NOTICE! There may be deposits inside the drainplugs/taps; the deposits must be cleaned away.Check that all coolant has indeed drained out.

3 Screw the drain plug (1) back.Remove the hose from the drain nipple (2) andput its protective cap back on.

2

P0014519

Maintenance

68 47704198 09-2016 © AB VOLVO PENTA

Charge Air Cooler, ExternalCleaning

IMPORTANT:Do not use a high pressure power washer.

1 Remove guards as necessary, to access theradiator.

2 Clean with water and a mild detergent. Use a softbrush. Be careful not to damage the radiator vanes.

3 Re-install the components

Cooling System, CleaningCooling performance is reduced by deposits in theradiator and cooling galleries. The cooling systemshould be cleaned out when the coolant is changed.

IMPORTANT:Cleaning must not be done if there is any risk of thecooling system freezing, since the cleaning solutiondoes not have any antifreeze properties.

IMPORTANT:It is extremely important that the correct concentrationand volume of coolant is added to the system.Mix in a separate clean vessel before filling the coolingsystem. Make sure that the liquids mix.

1 Empty the cooling system. Refer to Coolant,Draining, page 68.

2 Put a hose into the expansion tank filling hole andflush with clean water, as specified by Volvo Penta–refer to section Water quality in TechnicalData, page 85 until the water draining out iscompletely clear.

3 If there should still be some contamination left afterflushing for a long time, cleaning can be done withcoolant. Otherwise, continue as in item 8 below.

4 Fill the cooling system with 15-20 % mixture ofconcentrated coolant. Use only Volvo Pentarecommended concentrated coolant mixed withclean water.

P0014520

Maintenance

47704198 09-2016 © AB VOLVO PENTA 69

5 Drain the coolant after 1-2 days of operation.Remove the filler cap and possibly the lowerradiator hose to increase the speed of emptying.To prevent suspended material from settling backin the system emptying should be done rapidly,within the space of 10 minutes, when the enginehas not been standing still for a long time.

6 Flush the system immediately and thoroughly withclean hot water to prevent dirt from settling in theinner areas. Flush until the water that runs out iscompletely clean. Make sure that any heatercontrols are set to full heating during emptying.

7 If contamination should still be left after a longperiod of flushing, cleanout using Volvo Pentaradiator cleaner, followed by finishing-off with VolvoPenta neutralizer. Carefully follow the instructionson the package. Otherwise, continue as in item 8below.

8 When the cooling system is completely free fromcontamination, close the drain taps and plugs.

9 Fill up with Volvo Penta recommended coolant,following the instructions in the chapters entitledMaintenance, page 66 and Coolant Level,Checking and Topping Up, page 67.

Maintenance

70 47704198 09-2016 © AB VOLVO PENTA

Inlet and Exhaust System

Filling AdBlue®/DEF solution CAUTION!

AdBlue®/DEF spilt onto hot components will quicklyvaporize. Turn your face away!

CAUTION!Risk of corrosive damage.Contact with the fluid can cause irritation andcorrosion.Wear protective gloves!Change gloves and clothing that have been in contactwith the liquid.

IMPORTANT:Never start the engine if anything other than cleanAdBlue®/DEF solution has been added to the tank.

When topping off AdBlue®/DEF solution a nozzle witha built-in shut-off function should be used inaccordance with ISO standard 22241. These nozzlesare designed not to fit any other filling equipment.

The tank cover is blue and marked with the text'AdBlue/DEF only' to avoid confusion when filling.

Never fill with AdBlue®/DEF solution other than ISO22241 as specified by Volvo.If this instruction is not followed the aftertreatmentsystem may be permanently damaged. Engine powermay also be affected negatively and enginecomponents risk damage. Damage and costs arisingfrom a failure to meet these requirements are notcovered by Volvo Penta warranty obligations.

If AdBlue®/DEF solution is filled from a can or pumpthat lacks a stop function, it is important to make surethe tank is not overfilled as the solution may leak outof the breather tube. If the tank is overfilled and thesolution in it freezes at temperatures below -11°C(12.2°F), the tank and the hoses may be permanentlydamaged.

Take great care not to spill the solution as it isextremely corrosive toward many materials. If a spillshould occur the solution must be absorbed using drysand or other non-flammable material and handledaccording to local and national regulations. Avoid spillsonto soil and into waterways.

Maintenance

47704198 09-2016 © AB VOLVO PENTA 71

Erroneus filling of diesel or AdBlue®/DEF solution

IMPORTANT:The filling of diesel or AdBlue®/DEF solution in the wrong tank may result in damage to the engine.

In order to avoid confusion, the AdBlue®/DEF tank has a blue filler cap and a decal affixed to the tank.

Mistaken filling of AdBlue®/DEF solution in thediesel tank

Mistaken filling of diesel in the AdBlue®/DEFtank

• The engine will not run at full power or will notrun at all

• Injectors may be damaged

• Corrosion in the exhaust system between theturbocharger and aftertreatment system

• Expensive repairs

• The aftertreatment system may be seriouslydamaged

• The engine will no longer fulfill emission levelrequirements

• Expensive repairs

Maintenance

72 47704198 09-2016 © AB VOLVO PENTA

AdBlue/DEF Tank, Cleaning CAUTION!

Gloves must be changed. Take off contaminatedclothes.

1 Remove the drain plug (1) from the bottom of thetank and empty any remaining AdBlue/DEFsolution and coolant into a suitable recoverycontainer.

2 Remove the filler cap and undo the fillerassembly.

3 Immerse the filler cap and filler assembly in awater bath for at least 2 minutes.

P0013268 1

Maintenance

47704198 09-2016 © AB VOLVO PENTA 73

4 Undo and remove the tank fittings.

5 Check the strainer on the fittings: clean asnecessary.

NOTICE! Always replace a damaged strainer.

6 Flush the tank with hot water for at least 10minutes.Make sure the AdBlue/DEF tank is completelydrained of water afterwards.

p0013237

Maintenance

74 47704198 09-2016 © AB VOLVO PENTA

7 Reinstall the tank fittings.

8 Install the filler assembly.

9 Reinstall the drain plug (1) on the bottom of thetank with a new gasket.IMPORTANT!In order to avoid leakage the new gasket must beof a material that can withstand the AdBlue/DEFsolution; the genuine Volvo gasket fulfills thisrequirement.

10 Tighten the drain plug.15-liter tank – 30 Nm20/50-liter tank – 3 Nm

11 Fill the tank with AdBlue/DEF solution; refer toFilling AdBlue®/DEF solution, page 71. Install thefiller cap.

P0013268 1

Maintenance

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Electrical SystemThe engine is equipped with a 2-pole electrical systemand an alternator.

WARNING!Always stop the engine and break the current using themain switches before working on the engine.

IMPORTANT:Contact a Volvo Penta dealer for information if any arcwelding will be performed on the boat.Arc welding can cause damage to the engine and boatelectronics.

Main switchIMPORTANT:

Never disconnect the current using the main switcheswhen the engine is running.The alternator and electronics could be damaged.

The main switches must never be switched off beforethe engine has stopped. If the circuit between thealternator and the battery is disconnected when theengine is running, the alternator and electronics maybe damaged. For the same reason, the chargingcircuits must never be re-connected with the enginerunning.

FusesTwo circuit breakers are supplied with the engine wireharness. One 10 A to the EMS unit and one 150 A tothe air intake heater element. No other circuit breakersare supplied with the engine.

If a circuit breaker trips the engine will stop. If the circuitbreaker trips frequently, an authorized Volvo Pentaworkshop should be contacted to investigate the causeof the overload.

Electrical Connections

Check that electrical connections are dry, free fromoxide, and that they are securely tightened.

Maintenance

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Battery WARNING!

Risk of fire and explosion. Never allow an open flameor electric sparks near the battery or batteries.

WARNING!Battery electrolyte is a corrosive acid and should behandled with care. If you spill or splash electrolyte onany part of the body, immediately flush the exposedarea with liberal amounts of water and seek medicalattention as soon as possible.

WARNING!Ventilate the engine compartment before working onbatteries or battery connections.

IMPORTANT:Batteries can be damaged if they are left discharged,and can also freeze and burst easier in cold weather.If the engine is not going to be used for a longer periodof time, the batteries should be fully charged, tricklecharged if possible.

Maintenance

It is important to always follow the batterymanufacture’s recommendation and instruction whenreplacing and charging batteries. Depending onbattery type the instructions for maintenance andcharging may vary.Modern batteries are normally maintenance free, butthere are some actions that are recommended toincrease the battery service life and avoid accidents:

• Keep the batteries clean and dry. Contaminationand oxide on the batteries and battery poles cancause stray currents, voltage drop and discharge,especially in wet weather.

• Remove oxidation from the battery poles andterminals, using a brass brush.

• Tighten the terminals securely and grease them withterminal grease or petroleum jelly. Loose batteryconnections may cause damage to the engine’selectrical system.

• Charge the battery regularly. A battery that is keptfully loaded has a maximum service life. The easiestway to check if a battery needs charging is to use avoltmeter.

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P0002111

Maintenance

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Replacing BatteryIMPORTANT:

Make sure that the new battery fulfills the specificationsin Technical Data. Read the information supplied withthe battery before you begin the installation.

IMPORTANT:Do not disconnect the batteries with the engine runningas sensitive electrical components may beimmediately damaged.

WARNING!Never confuse the positive and negative poles on thebatteries. Risk of arcing and explosion.

Disconnecting

1 Untighten the nut and remove the – cable (black).

2 Untighten the nut and remove the + cable (red).

3 Remove the battery.

Connecting

1 Place the new battery.

2 Connect the + cable (red) to the + pole on thebattery and tighten the nut.

3 Connect the – cable (black) to the – pole on thebattery and tighten the nut.

NOTICE! Hand the old battery to a re-cycling station.

-+

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Maintenance

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StorageTo prevent the engine and other equipment from being harmed during long (2 months or more) periods out ofservice, it must be conserved. Conservation protects the engine from freezing and corrosion damages.

It is of utmost importance that the conservation is performed correctly, therefore we have compiled a checklistcovering the most important points. Before taking the engine out of service for long periods, it is recommendedthat the engine is checked by a Volvo Penta dealer for possible need for overhaul or repair.

CAUTION!Read the chapter on Maintenance before starting work. It contains instructions on how to carry out maintenanceand service operations in a safe and technical correct manner.

WARNING!Conservations oils can be flammable and dangerous to inhale. Ensure good ventilation. Use a protective facemask when spraying.

IMPORTANT:Washing with a power washer: Never aim the water jet at radiators, charge air cooler, seals, rubber hoses orelectrical components.

• For up to 8 month’s stoppage:Change the oil and oil filter on the engine, then runthe engine until warm.More than 8 month's stoppage:Conserve the lubrication and fuel systems withconservation oil. Refer to the section Conservationof the lubrication and fuel systems for more than 8months’ stoppage.

• Make sure the coolant has adequate antifreezeproperties. Top up as necessary.Alternatively, you can drain the coolant (also drainthe coolant filter).

• Drain any water and contamination from the fuelfilters and fuel tank. Fill the fuel tank completely, toavoid condensation.

• Disconnect the battery cables, clean and charge thebatteries. Trickle charge the batteries while theequipment is in storage. A poorly charged batterycan freeze and burst.

• Clean the outside of the engine. Do not use a highpressure washer for engine cleaning. Touch uppaint damage with Volvo Penta original paint.

• Put a note on the engine with the date, type ofconservation and the conservation oil used.

• Cover the air filter, exhaust pipe and engine ifnecessary.

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Bringing out of storage• Remove any covers from the engine, air filter

and exhaust pipe.

• Fill the engine with the correct grade of oil intothe engine, as necessary, refer to TechnicalData, Lubrication System. Install a new oil filterif the filter was not changed during conservation.

• Install new fuel filters and bleed the fuel system.

• Check the drive belt(s).

• Check the condition of all rubber hoses, andretighten the hose clamps.

• Close the drain taps and install any drain plugs.

• Check the coolant level. Top up as necessary.

• Connect the fully charged batteries.

• Start the engine and warm it up at fast idle withno load.

• Check that no oil, fuel or coolant leakage occurs.

Conservation of the lubrication and fuel systems for more than 8 months’ stoppage:• Drain the engine oil and fill up with conservation

oil* to just over the MIN marking on the dipstick.

• Connect the fuel suction and return hoses to a 1/3full jerrican containing conservation oil* and 2/3diesel fuel.

• Bleed the fuel system.

• Start the engine and run at a fast idle until about 2liters (0.6 US gal) of the fluid in the jerrican havebeen used. Stop the engine and re-connect the fuelsuction and return lines.

• Drain the conservation oil from the engine.

• Follow the other instructions on the previous page.* Conservation oils are sold by oil companies.

Storage

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Technical Data

EnginesType Designation TAD560VE, TAD561VE

TAD761VE, TAD762VE, TAD763VE, TAD764VE, TAD765VEPower Refer to the sales literatureTorque Refer to the sales literatureNo. of cylinders 6Bore 108 mm (4.25")Stroke 130 mm (5.12")Cylinder volume 7.15 dm3 (436 in3)Weight* 650 kg (1,433 lbs)Firing order 1-5-3-6-2-4Compression ratio 17:1Low idle 600 rpmHigh idle 2.200 rpm

*only engine, excluding cooling system

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Lubrication SystemOil change volume, including filter change

Oil pan, standard 29 l (7.7 US gals)

Oil PressureEngine oil operating temperature, min. 120 °C (248 °F)

At rated engine rpm 420–450 kPa (61–65 PSI)

Automatic stop at pressure lower than 100 kPa (15 PSI)

Oil filterFull flow filter 1 pc. (tighten 1/2–3/4 turn after it touches)

Lube Oil PumpType Gear driven

Oil Grade and Oil Change Interval

Oil recommendationsOil quality Oil change interval, reached first in operation:VDS-3 600 hours or 12 months

IMPORTANT:Only Volvo hybrid oil 15W-50 may be used for installations with Start / Stop function.

NOTICE! Sulfur content in fuel must not exceed 15 ppm.NOTICE! Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the qualityrequirements above.

VDS = Volvo Drain Specification

Viscosity

Select the viscosity according to the table.

The temperature values refer to stable ambienttemperatures.

* SAE 5W/30 refers to synthetic or semi-synthetic oils.

Technical Data

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Fuel SystemFeed pumpFeed pressure at 600 rpm min 100 kPa (14.5 psi)Feed pressure at 1200 rpm min 300 kPa (43,5 psi)Feed pressure at full load min 300 kPa (43,5 psi)

Bypass valveOpening pressure 400-550 kPa (58–80 psi)

Fuel quality requirements for Diesel Engines with catalystsGeneral fuel requirementsThe fuel quality is essential for engine function, durability and emission compliance. Only fuels meeting relevantlegal requirements and national and international standards shall be used; such as European EN590 diesel andNorth American ASTM D975 diesel.Usage of fuels or fuel blends that do not comply with the below specifications given in this document isnot allowed and Volvo Penta will not accept warranty in case of fuel related engine damages.

Diesel fuel requirementsAn insufficient cetane number (“ignitability”) leads to poor startability and increased exhaust emissions.Requirement; cetane number min 40 for acceptable engine function.

Insufficient density and viscosity will reduce the power and increase the fuel consumption.Excessive density and viscosity will endanger the durability and function of the fuel injection equipment.Requirement; viscosity 1.5-4.5 mm2/s (cSt) at 40 °C and density 800-860 kg/m3 at 15 °C.

Sufficient fuel lubricity is essential to protect the fuel injection system against excessive wear.Requirement; wear scar max 520 μm in the HFRR test (ISO 12156)

Excessive sulfur content will damage the catalytic system.Requirement; the max allowed sulfur content is 15 ppm.

Water will give corrosion and wear of engine parts and enables microbial growth in the fuel tank.Organic contaminants (bacteria, fungi etc.) can block fuel filters and inorganic contaminants (dust, sand) cancause severe damage to the fuel injection system.Requirement; max allowed water content 200 ppm and max allowed total contaminant content 30 ppm.

Cold flow properties are determined by the cloud point (the temperature when wax crystals start to fall out) andthe CFPP (cold filter plugging point). The oil companies are always responsible for providing fuels with the correctcold flow properties for any time of the year.

FAME (“biodiesel”) is blended into diesel fuel, but excessive FAME content will damage the catalytic system.Requirement; the max allowed FAME content is the same as in fuel EN590 (at present 7% FAME thatcomplies with EN 14214) respectively ASTM D975 (at present 5% FAME that complies with ASTM D6751).

NOTICE! Higher FAME blends will damage the catalytic system and may negatively impact performance,emissions and fuel consumption and the function of the exhaust aftertreatment system will also be negativelyaffected.NOTICE! Engines for emergency applications, e.g. standby genset , may only run with market diesel fuel withminimum FAME content.NOTICE! In case of cold starting problems shift to diesel fuel with minimum FAME content. It is recommendednot to use FAME below -10°C.

Technical Data

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Paraffinic fuels (“Synthetic Diesel”) - HVO and GTLHVO (Hydro-treated Vegetable Oil) are renewable, and GTL (Gas-To-Liquid) are fossil, paraffinic fuels. Usage ofparaffinic fuels will give lower emissions, but also marginally higher fuel consumption.NOTICE! Volvo Penta approves usage of neat HVO and GTL that complies with EN 15940, as well as HVO andGTL blends into diesel fuels complying with the quality requirements above.

Kerosene (“Jet fuel”)Kerosene has low cetane number, low viscosity, low lubricity and high sulfur content compared to diesel fuels.NOTICE! Usage of kerosene is not allowed.

AdditivesThe oil companies shall always ensure that their fuels meet relevant requirements and are fit for their purpose.Their responsibility includes any use of additives for proper engine performance and function.NOTICE! It is not allowed to add secondary treatment additives ("diesel boosters"), lubricants, gasoline or alcoholinto the fuel tank.

Technical Data

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Cooling SystemType Pressurized, sealedPressure cap, max. opening pressure 110 kPa (16.0 psi)Volume (engine)TAD560–61VE 7,5 liter (2,0 US gals)TAD761–65VE 9,8 liter (2,6 US gals)

ThermostatQuantity and type 1 pc. piston thermostatOpening temperature 86 °C (187 °F)Fully open at 98 °C (208 °F)

CoolantVolvo Penta Coolant VCS and VCS Ready Mixed(yellow) are based on Organic Acid Technology, OAT.

IMPORTANT!Different types of coolant must not be mixed with eachother.

Water Quality

ASTM D4985:

Total solid particles <340 ppmTotal hardness <9,5° dHChloride <40 ppmSulfate <100 ppmpH value 5.5–9Silica (acc. ASTM D859) <20 mg SiO2/l

Iron (acc. ASTM D1068) <0.10 ppmManganese (acc. ASTM D858) <0.05 ppmConductivity (acc. ASTM D1125) <500 µS/cmOrganic content, CODMn (acc.ISO8467)

<15 mg KMnO4/l

coolant vcs ready mixed

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Technical Data

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Electrical SystemSystem voltage 24V

AlternatorVoltage/max. current 28V/80A

Technical Data

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Identification NumbersLocation of engine platesThe engines are supplied with two engine plates, of which one is installed on the right side of the cylinder blockand the other on top of the valve cover.

Engine Model Spec.No Serial No kw(G)redkw(G)red

rm

Kw(S)red

C

Kw(G) Kw(S)

Kw(W)

MAID IN GERMANY

1/min

7

MODELKW

RPM KwredHP

TIM BTDCFUEL RATE

DISPL

CODESPECAdd

mm /3STR

L

SER NOC.SPEC

VALVE LASH MM IN

MADE IN GERMANY

EXH

01223270

EP

MODELKW

RPM KwredHP

TIM BTDCFUEL RATE

DISPL

CODESPECAdd

mm /3STR

L

SER NOC.SPEC

VALVE LASH MM IN

MADE IN GERMANY

EXH

01223270

EP

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 P0003613

1 Engine Designation 10 Injection angle and camshaft type2 Engine power, without fan (kw) 11 Displacement, total3 Not in use 12 Injection volume4 Engine power, without fan (hp) 13 Not in use5 Not in use 14 Certification approval number6 Manufacture’s ID code 15 Valve clearance, inlet valvel (mm3/slag )7 Serial number (10 didgits) 16 Valve clearance, exhaust valve (mm3/slag)8 Engine specification number 17 EP code for injection pump (cyl 1 först)9 Engine Speed 18 Further information

Technical Data

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Engine serial number

The engine serial number is stamped on the engineblock and the product plate. The serial numberconsists of 10 digits. Only the last eight digits arestamped on the engine block.

Engine data (refer to engine plate below)

Engine model (1): ..............................................................................................................................

Specification number (2):

..............................................................................................................................

Serial number (3):

..............................................................................................................................

Nearest Volvo Penta workshop

Name: ..............................................................................................................................

Address:

..............................................................................................................................

Telephone:

..............................................................................................................................

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Technical Data

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Declaration for the installation of partially-completed machinery in accordance withMachinery Directive 2006/42/EC

Engine Manufacturer:AB Volvo PentaGropegårdsgatanSE 405 08 GöteborgSweden

Description of engine 4–cycle diesel engine. Engine types coverd by this declaration:TAD560VETAD561VE

TD520GETAD530GETAD531GETAD532GETAD550GETAD551GE

TAD620VETAD650VETAD660VE

TAD720VETAD721VETAD722VETAD750VETAD760VETAD761VETAD762VETAD763VETAD764VETAD765VE

TD720GETAD720GETAD730GETAD731GETAD732GETAD733GETAD734GETAD750GETAD751GETAD752GETAD753GETAD754GE

Fundamental health and safety requirements applied to, and fulfilled by, the above-mentioned engines aredescribed in the following items in Annex I:1.6.1, 1.6.2, 1.6.4, 1.7.1, 1.7.1.1, 1.7.1.2, 1.7.4, 1.7.4.1, 1.7.4.3The relevant technical documentations is compiled as described in part B of Annex VII.Relevant information concerning the partially-completed machinery will be provided in suitable form upon justifiedrequests from competent national authorities. The individual authorized to compile the relevant technicaldocumentation is the signer of this declaration.

The partially-completed machinery also complies with the following relevant Directive:2014/30/EU – Electromagnetic Compatibility (EMC) Directive.Applied standards: EN 61000–6–1, EN 6100–6–2, EN 61000–6–3, EN 61000–6–4, EN 12895, EN-ISO 14982and EN 13309.

For engines equipped with the Volvo Penta Start/Stop System the responsibility for the functional safety of thesystem lies with the machine manufacturer performing the integration.

The engines covered by this declaration may not be put into operation before the completed machinery into whichthey are to be installed has been declared to conform with the provision of Machinery Directive 2006/42/EC.

Name and function:Jennifer Åhlberg, Laws and Regulation(The identity of the individual authorized to sign on behalf of the engine manufactureror the latter’s authorized representative.)

Signature and title:

Date and place of issue: (yyyy-mm-dd) 2016–08–30 Gothenburg LR-21/16–01

Technical Data

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AAdBlue/DEF Tank, Cleaning..................................... 73After Engine Shutdown..............................................42Air Filter, Change...................................................... 56Alarms....................................................................... 39Auxiliary stop............................................................. 41BBattery....................................................................... 77Before Engine Shutdown...........................................41Before Starting.......................................................... 35CCharge Air Cooler, External Cleaning....................... 69Charge Air Pipe, Leakage Check.............................. 57CIU (Control Interface Unit).......................................33Coolant Level, Checking and Topping Up.................67Coolant, Draining.......................................................68Cooling System, Cleaning......................................... 69DDCU (Display Control Unit)....................................... 36DCU (Display Control unit)........................................ 43Display Control Unit...................................................23Draining condensate, fuel system............................. 62Drive Belt, Check and Change.................................. 58DU (Display Unit).................................................29, 43EEasy Link Instruments......................................... 33, 44EATS (Exhaust Aftertreatment System)....................14EATS Warnings and Inducements............................ 48Electrical Connections...............................................76Emission Aftertreatment System............................... 10EMS (Engine Management System)......................... 13Engine Fuel Filter Replacement................................ 63Engine, General........................................................ 55Engines............................................................... 12, 81Erasing fault codes....................................................45FFault Tracing............................................................. 46Filling AdBlue®/DEF solution.................................... 71Fuel Pre-filter, Change.............................................. 64Fuel System........................................................ 62, 83Fuel system, bleeding............................................... 65IIdentification Numbers...............................................87Inlet and Exhaust System..........................................71MMain switch................................................................76Major Components.................................................... 17Maneuvering..............................................................40NNever Use Start Spray.............................................. 38OOil filter, Change........................................................60Oil Grade and Oil Change Interval............................ 82Oil level, checking and topping up.............................59Operation at low load................................................ 40Orientation.................................................................54

PPrinciple solution....................................................... 18RReading the Instruments........................................... 39SStarting in Extreme Cold........................................... 37Starting the Engine....................................................36Starting Using Auxiliary Batteries.............................. 38Stop/Start.................................................................. 34VViscosity.................................................................... 82Volvo Penta Action Service....................................... 11Volvo Penta Dealer Network..................................... 11WWater Quality.............................................................85

Index

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© 2016 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper

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Documents

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