Volvo TAD1345GE User's Guide

User guide and maintenance manual VVOOLLVVOO EEnnggiinnee TTAADD11334433GGEE TTAADD11334444GGEE TTAADD11334455GGEE 7748641

Electrical SystemDisconnect the powerBefore any work is done on the electrical system, theengine must be stopped and the power removed byswitching off

IntroductionThis Operator's Manual refers to the industrial enginesTAD1341GE, TAD1342GE, TAD1343GE,TAD1344GE, TAD1345GE, TAD1350GE,TAD1351GE, TAD

WarrantyYour new Volvo Penta industrial engine is covered bya limited warranty, according to the conditions andinstructions compiled in the Warranty a

Certified EnginesIf you own an emission-certified engine used in anarea where exhaust emissions are regulated bylaw, it is important to be aware of th

PresentationEMS (Engine ManagementSystem)EMS (Engine Management System) is an electronic system with CAN communication (Controller Area Network)for di

Instruments and ControlsDCU (Display Control Unit)The DCU (Diesel Control System) control panel isavailable as an optional accessory for the EMS(Engin

MenusThere are several sub-menus under each main menu.There is not space for all the menu choices on the dis-play. To scroll through the menus, use th

Preheatmanual activation of pre-heating. When it is activated,the EMS system senses at start-up if pre-heating isneeded. For automatic pre-heating, re

Setupparameter setting in the engine's control systems. Dif-ferent menus appear under Customer parameter,depending on whether Versatile or Gen se

Customer parameter / Gen set•Primary engine speed - selection of engine rpm,1500 or 1800 rpm.•Preheat on ignition - activation of automatic pre-heatin

Display settingsettings for the display. Adjustment is made with the7 and 9 buttons; see DCU panel illustration.•Set contrast (%) - contrast setting.•

CIU (Control Interface Unit)The CIU is a "translator" between the control unit(EMS) and the customer's own control panel. The CIUhas tw

StartingMake it a habit of giving the engine and engine room a visual check before starting. This will help you to discoverquickly if anything abnorma

Starting the EngineEMS (Engine Management System)The pre-heating time is adjusted to suit the enginetemperature, and can last for up to 50 seconds bot

Starting in Extreme ColdCertain preparations must be made to facilitate enginestarting, and in some cases to make starting possibleat all:•Use a winte

Starting Using Auxiliary Batteries WARNING!Explosion hazard. Batteries contain and give off anexplosive gas which is highly flammable and explosive.A

OperationCorrect operating technique is very important for both fuel economy and engine life. Always let the engine warmup to normal operating tempera

Engine ShutdownDuring longer breaks in operation, the engine must be warmed up at least once every two weeks. This preventscorrosion in the engine. If

Extra StopFor location of the extra stop, please refer to Mainte-nance page 46. WARNING!Working with or going close to a running engine is asafety ri

OPERATOR’S MANUALGenerating set and industrial engines13 liter (EMS 2)

Fault HandlingFault TracingA number of symptoms and possible causes of engine malfunctions are described in the table below. Alwayscontact your Volvo

1 Discharged batteries2 Poor contact/open circuit in electrical wiring3 Main switch turned of4 Main fuse faulty5 Faulty ignition lock6 Faulty main rel

Diagnostic FunctionThe diagnostic function monitors and controls that theEMS system functions normally. The diagnostic func-tion has the following tas

Active and Inactive FaultsActive faultsAt the same time, the fault is stored in the control unitmemory. When the fault has been attended to and theign

Reading fault causes via the DCU (Display ControlUnit)When a fault code is set, the following text is shownon the display:!! ENGINE WARNING !!alternat

Fault Code RegisterNo fault (Code 1.1)Cause Reaction RemedyThere are no active faults.Preheating Relay (Code 5.4, PID 45/SPN 626)Cause Reaction Remedy

Oil Level Sensor (Code 5.9, PID/SPN 98)Cause Reaction Remedy• Shorted to plus (+) or minus(-)• Break• None • Check that the cable harnessto the oil le

Boost Pressure Sensor (Code 3.4, PID/SPN 102/106)Cause Reaction Remedy• Short circuit to positive (+) orearth (ground) (–)• Open circuit• Engine smoke

Coolant Temperature Sensor (Code 3.3, PID/SPN 110)Cause Reaction Remedy• Short circuit to positive (+) orearth (ground) (–)• Open circuit• Preheating

Crankcase Ventilation Pressure Sensor (Code 7.8, PID/SPN 153)Cause Reaction Remedy• Shorted to plus (+) or minus(-)• Break• None • Check that the cran

CALIFORNIA PROPOSITION 65 WARNINGEngine exhaust, some of its constituents, and a broad range of engine parts are known to the State ofCalifornia to

Oil Temperature (Code 5.8, PID/SPN 175)Cause Reaction Remedy• Oil temperature is too high • The engine control modulelimits engine output(unlessprotec

Piston Cooling Pressure Sensor (Code 6.8, PPID 8/SPN 520192)Cause Reaction Remedy• Shorted to plus (+) or minus(-)• Break• None • Check that the pisto

Injector, Cylinder #2 (Code 7.2, SID 2/SPN 652)Cause Reaction Remedy• Electrical fault• Faulty compression or injec-tor• Engine runs on 5 cylinders• A

Injector, Cylinder #6 (Code 7.6, SID 6/SPN 656)Cause Reaction Remedy• Electrical fault• Faulty compression or injec-tor• Engine runs on 5 cylinders• A

Preheating Sensor (Code 8.6, SID 70/SPN 729)Cause Reaction Remedy• Fault in cable harness• Fault in preheating relay• Preheating can not be acti-vated

Data Set Memory EEPROM, CIU (Code 9.8, SID 253/SPN 630)Cause Reaction Remedy• Internal fault in control mod-ule• Programming faulty• Engine does not s

Fan actuator (SID 33/SPN 975)Cause Reaction Remedy• Short circuit to positive (+) ornegative (-)• Open circuit• Fan actuator damagedmechanically• Warn

Maintenance ScheduleService ScheduleFSI = First Service InspectionS2 = First Time ServiceS = Lubrication serviceA – F = Type of service (regular servi

B Every 1000 Hours / at Least Every 12 MonthsFuel Filter RAir filter insert , engine RFuel pre-filter RCoolant Filter(1)R1) Not at same time as coolan

MaintenanceThis chapter describes how the specified maintenance points in Service Schedule page 43 should be performed,where also service intervals ar

ContentForeword ... 2Safety Information ...

81011121314P000431867123459 1. Extra stop2. Combined charge air pressure and charge airtemperature sensor3. Oil pressure sensor4. Crankcase pressure s

Engine, GeneralGeneral inspectionMake it a habit to give the engine and engine bay avisual inspection before starting the engine and afteroperation on

Charge Air Pipe, Leakage CheckInspect the condition of the charge air hoses, hoseunions and clamp condition for cracks and other dam-age. Change as ne

Alternator Belts, ChangeIMPORTANT!Always replace a drive belt that seems worn or iscracked.1 Disconnect the main switch(es) and check that theengine i

Lubrication SystemOil change intervalls may vary according to the lubri-cation oil grade and fuel sulfur content. Refer to Tech-nical data, Lubricatio

Engine Oil, Change WARNING!Hot oil and hot surfaces can cause burns.Oil changes must be done when the engine is warm.1 Connect the drain hose to the o

Fuel SystemOnly use the grades of fuel recommended in the fuelspecification below, please refer to TechnicalData page 68. Always observe the greatest

Fuel Pre-filter, Change1 Undo the cable from the water trap sensor.2 Remove the water trap filter from the filter bracket.Collect any spilled fuel in

Cooling SystemThe engine's internal cooling system makes sure theengine works at the right temperature. It is a closedsystem that must always be

Coolant, MixingThe concentrated coolant must be mixed with purewater (distilled or de-ionized water) according to spec-ifications; refer to Water Qual

ForewordVolvo Penta engines are used all over the world. They are used in all possible operating conditions. This is not acoincidence. After 100 years

Coolant Level, Checking andTopping UpCoolant filling must be performed with the engine stop-ped. Check the coolant level daily before starting.IMPORTA

Coolant, Draining WARNING!Do not open the coolant filler cap when the engine iswarm, except in emergencies, this could cause seriouspersonal injury. S

Coolant Filter, ChangeNOTICE! Only applies to engines using Volvo PentaCoolant (green). Engines using Volvo Penta CoolantVCS are not fitted with coola

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

Electrical SystemThe engine is equipped with a 2-pole electrical systemand an alternator. System voltage is 12V or 24V. WARNING!Always stop the engine

Battery, Maintenance WARNING!Risk of fire and explosion. Never allow an open flameor electric sparks near the battery or batteries. WARNING!Never conf

FillingThe electrolyte level should be 5–10 mm (0.2– 0.4”)above the cell plates in the battery. Top up with distilledwater as required.After filling,

•Charge batteries if they have become discharged.During charging, unscrew the cell plugs but leavethem in the plug holes. Ventilate well, especially i

StorageThe engine and other equipment must be laid up to prevent damage if they are not used for two months or more.It is important that this is done

Bringing out of storage• Remove any covers from the engine, air filterand exhaust pipe.• Put the correct grade of oil into the engine, ifnecessary, re

Safety InformationRead the Operators Manual through very carefully before you start the engine or do any maintenance or service.It has to do with your

Technical DataEnginesType designation TAD1341/42/43/44/45GEPower, Prime/Stand-by Refer to the sales literatureTorque, Prime/Stand-by Refer to the sale

Lubrication SystemOilChange volume, including filter change, liter/US gal 36 / 9.5Oil pressure, hot engineat operating speed, kPa/psi 370-520 / 54–75a

ViscositySelect the viscosity from the adjacent table, for theappropriate continuous ambient air temperature.*Refers to synthetic or semi-synthetic oi

ConditionsVolvo Penta engines of above are able to run with fuel blends containing up to 30% FAME under specific condi-tions:• Oil quality VDS-3 or VD

Cooling SystemType Preassurized, sealedPressure cap, max opening pressure, kPa/psi 70 / 10.2Volume (engine), liter US gal 20 / 5.28Volume (engine+radi

Identification Numbers123P0002050 1Chassis and serial number2A Engine designationB Engine power, net, (without fan)C Max. engine speedD Main softwareE

Fundamental health and safety requirements applied to, and fulfilled by, the above-mentioned engines are described in the following items in Annex I; 1

Operator's Manual OrderThis Operator’s Manual may be ordered in a differentlanguage free of charge up to 12 months after delivery,via internet.Pl

After Engine Shutdown... 23Air Filter, Check and Change... 47Alarms...

Safety rules for operation and maintenanceDaily checksMake it a habit to give the engine and engine bay avisual check before starting (before the engi

© 2010 AB VOLVO PENTA Volvo reserves the right to make changes Printed on environmentally friendly paper

7748641  English  06-2010

Care and maintenanceKnowledgeThe Operators Manual contains instructions for doingthe most common service and maintenance tasks ina safe and correct ma