Volvo Penta TAD550GE User manual

Operator’s manual
TAD550GE, TAD551GE
TAD750GE, TAD751GE, TAD752GE, TAD753GE, TAD754GE

WARNING! Operating, servicing and maintaining an engine can expose you chemi-
cals including engine exhaust, carbon monoxide, phthalates, and lead which are known to
the State of California to cause cancer and birth defects or other reproductive harm.
Breathing diesel engine exhaust exposes you to chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
To minimize exposure, avoid breathing exhaust when operating, servicing and maintaining
the engine.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Wear gloves or wash your hands frequently when servicing the vessel.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65warnings.ca.gov
www.p65warnings.ca.gov/products/diesel

Table of Content
Foreword ...................................................................................................... 3
Safety Information ...................................................................................... 4
Introduction ............................................................................................... 14
Fuel, oils and coolant .............................................................................. 15
Maintenance and replacement parts ....................................................... 16
Excessive strain on a product and components ...................................... 16
Environmental care ................................................................................. 17
Volvo Penta Dealer Network ................................................................... 19
Volvo Penta Action Service ..................................................................... 19
Presentation .............................................................................................. 20
Engines .................................................................................................. 20
EMS (Engine Management System) .................................................... 21
Instruments and Controls ........................................................................ 22
Display Control Unit .............................................................................. 22
DU (Display Unit) ................................................................................... 29
CIU (Control Interface Unit) .................................................................. 33
Easy Link Instruments .......................................................................... 33
Starting ...................................................................................................... 34
Before Starting ...................................................................................... 34
Starting the Engine ............................................................................... 35
DCU (Display Control Unit) .................................................................. 35
Starting in Extreme Cold ...................................................................... 36
Never Use Start Spray ......................................................................... 37
Starting Using Auxiliary Batteries ......................................................... 37
Operation ................................................................................................... 38
Reading the Instruments ...................................................................... 38
Alarms .................................................................................................... 38
Maneuvering .......................................................................................... 39
Operation at low load ........................................................................... 39
Engine Shutdown ...................................................................................... 41
Before Engine Shutdown ..................................................................... 41
Stop the Engine ..................................................................................... 41
Auxiliary stop ........................................................................................ 42
After Engine Shutdown ........................................................................ 42
Fault handling ........................................................................................... 43
Diagnostic Function ................................................................................. 43
DU (Display Unit) .................................................................................... 43
CIU (Control Interface Unit) ..................................................................... 44
Easy Link Instruments ............................................................................. 45
Erasing fault codes .................................................................................. 45
Fault Tracing .......................................................................................... 46
Maintenance Schedule ............................................................................. 48
Maintenance .............................................................................................. 49
Orientation ............................................................................................. 50
Engine, General ..................................................................................... 53
Charge Air Pipe, Leakage Check ......................................................... 53
Drive belt, check and change ............................................................... 53
Drive belt, check and change ............................................................... 55
Lubrication System ............................................................................... 56
Oil level, checking and topping up ....................................................... 56
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Oil filter, Change .................................................................................. 57
Oil filter, Change .................................................................................. 58
Engine Oil, Change .............................................................................. 59
Fuel System ........................................................................................... 60
Draining condensate, fuel system ........................................................ 60
Engine Fuel Filter Replacement ........................................................... 61
Engine Fuel Filter Replacement ........................................................... 62
Fuel Pre-filter, Change ......................................................................... 63
Fuel system, bleeding .......................................................................... 64
Cooling System ..................................................................................... 65
Coolant Level, Checking and Topping Up ........................................... 66
Coolant Level, Checking and Topping Up ........................................... 67
Coolant, Draining ................................................................................. 68
Coolant, Draining ................................................................................. 69
Charge Air Cooler, External Cleaning .................................................. 70
Cooling System, Cleaning .................................................................... 70
Electrical System .................................................................................. 72
Main switch .......................................................................................... 72
Fuses ................................................................................................... 72
Electrical Connections ......................................................................... 72
Battery .................................................................................................. 73
Technical Data ........................................................................................... 75
Engines .................................................................................................. 75
Lubrication System ............................................................................... 76
Viscosity ............................................................................................... 76
Fuel System ........................................................................................... 77
Cooling System ..................................................................................... 80
Water Quality ....................................................................................... 80
Electrical System .................................................................................. 81
Identification Numbers ......................................................................... 82
Index ........................................................................................................... 85
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Foreword
Welcome!
Volvo Penta engines are designed to fulfill Volvo’s core values; quality, safety
and environmental care. After more than 100 years as en engine manufacture,
the Volvo Penta brand has also become a symbol of reliability, technical
innovation, top-of-the-range performance and long service life. Volvo Penta
engines are used all over the world, in all possible operating conditions.
Make sure to thoroughly read through the Operator’s Manual regarding
operating and maintenance. It contains the information you need to be able to
operate and maintain the engine safely and correctly. Pay careful attention to
the safety instructions included in the manual.
As the owner of a Volvo Penta engine, you become part of a worldwide network
of dealers and service workshop that assist you with technical advice, service
requirements and replacement parts. Contact you nearest authorized Volvo
Penta dealer for assistance.
It is possible to buy additional literature about your Volvo Penta engine, e. g.
the Service & Maintenance manual. More information on how to do this can be
found at www.volvopenta.com.
Information about your closest Volvo Penta dealer and other useful news
and information can be found at www.volvopenta.com and by following
Volvo Penta on Facebook.
www.volvopenta.com
www.facebook.com/volvopenta
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Safety Information
This chapter describes how safety precautions are
presented in the manual and on the product. Read the
chapter 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.
It also gives you an introduction to the basic safety
rules for using and looking after the engine.
If anything remains unclear or if you are unsure of
something, contact your Volvo Penta dealer for
assistance.
IMPORTANT:
Always follow local safety instructions and
regulations.
Safety texts have the following order of priority:
DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.
WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT:
Indicates a situation, which, if not avoided, could result in property damage.
NOTICE! Used to draw attention to important information that facilitates work or
operations.
!
This symbol is may be used on the product to call your attention to the fact that this is
safety information. Always read such information very carefully.
Make sure that warning and information symbols on the engine are clearly visible and
legible. Replace symbols that have been damaged or have been painted over.
In some cases, this symbol is used on our products and refers to important information
in the Operator’s Manual.
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Most chemicals such as engine and transmission oils,
glycol, petrol and diesel oil and chemicals used in
workshops such as degreasing agents, paint and
solvents are harmful to health.
Carefully read the instructions on the product
packaging! Always follow the safety regulations, such
as the use of protective masks, goggles, gloves, etc.
Make sure that other personnel are not exposed to
substances that are hazardous to health. Ensure good
ventilation.
Manage used and leftover chemicals in the prescribed
manner.
Daily Checks
WARNING!
Do not start the engine if there is reason to suspect fuel
leaks or if there is explosive material nearby.
Make it a habit to give the engine and engine
compartment a visual check before the engine is
started and after operations, once the engine has
stopped. This helps you to quickly discover fuel,
coolant or oil leakages or any other abnormality that
has occurred, or is about to occur.
Personal safety equipment
CAUTION!
Always use appropriate safety equipment. Personal
protective equipment does not eliminate the risk of
injury but it will reduce the degree of injury if an
accident does happen.
Some examples are ear protection, eye and face
protection, protective footwear, personal protective
equipment, head protection, protective clothing,
gloves and respirators.
WARNING!
Ensure that all machine guards and safety devices are
in place and are functional.
CAUTION!
Never use tools or products that show signs of
damage.
P0024482
Safety Information
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Protect your eyes
CAUTION!
Wear safety glasses.
Always wear safety glasses if there is a risk of
splintering, sparks and spray from the electrolyte (so-
called battery acid), or other chemicals. Your eyes are
very delicate and damage can result in loss of sight!
Protect your skin
CAUTION!
Risk of skin damage.
Avoid getting oil on your skin! Prolonged or repeated
exposure to oil can dry out the skin. Thereafter,
irritation, dryness and eczema and other skin problems
may occur.
Use protective gloves and avoid oil-soaked clothes
and rags. Wash regularly, especially before eating.
Wear suitable protective creams to prevent skin from
drying out and to facilitate cleaning.
Fire safety
WARNING!
Fire and Explosion Risk!
Accidental spark could ignite fuel vapors.
All fuels – as well as many lubricants and chemicals –
are flammable. Do not allow open flames or sparks
near them. Smoking forbidden! Hydrogen from the
batteries is also very flammable and explosive in
certain mixture with air.
Ensure that the workplace is well ventilated and take
the necessary precautions before welding or grinding
begins. Always ensure that there is a fire extinguisher
close at hand in the work area.
P0024470
Safety Information
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Spare parts — safety
WARNING!
Always use spare parts with the same quality as
genuine Volvo Penta parts to minimize the risk of an
explosion or fire.
Components in fuel systems and electrical systems on
Volvo Penta engines are designed and manufactured
to minimize the risk of explosions and fire, in
accordance with applicable legal requirements.
Used oils, filters and chemicals etc.
WARNING!
Risk of fire.
Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire.
Oil-soaked rags can spontaneously ignite under
certain circumstances.
IMPORTANT:
Used fuel and oil filters are environmentally hazardous
waste and must be taken to an approved waste
management facility for correct handling, as must any
used lubricating oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.
Prevent start of the engine
WARNING!
Immobilize the engine by turning off the power supply
with the main switch(es) and lock it (them) in the off
position before starting work. Place a warning notice
at the main switch.
If the engine is equipped with BMS (Battery
Management System), always disconnect both battery
cables from the battery terminals.
Ventilation when running the engine
WARNING!
Only start the engine in a well-ventilated area. If
operating the engine in a closed area ensure that there
is exhaust ventilation leading out of the work area to
remove exhaust gases and crankcase ventilation
emissions.
The engine must not be operated in areas where there
are explosive materials or stored gas.
P0024481
Safety Information
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Rotating parts and hot surfaces
DANGER!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
If the engine is in operation and operates another
device, you must not, under any circumstances,
staying close to the engine.
Work on running engines is strictly prohibited. There
are however adjustments that require the engine to be
run. Approaching a running engine is a safety risk.
Loose clothing and long hair can get caught in the
rotating parts; careless movements or a dropped tool
can lead to serious personal injury.
Be careful to avoid hot surfaces (exhaust pipes,
turbochargers, charge air manifolds, start elements
etc.) and hot fluids in pipes and hoses on engines that
are running or have just stopped. Re-install all
protective covers that were removed during
maintenance work before starting the engine.
Information on the engine
IMPORTANT:
Make sure that all warning and information decals on
the product are always visible. Replace decals which
have been damaged or painted over.
Prohibition on use of start spray
WARNING!
Never use start spray or similar agents to start an
engine. This may cause an explosion in the inlet
manifold. Risk of personal injury.
P0024808
P0024483
Safety Information
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Before start of engine
WARNING!
Never start the engine if there is reason to suspect fuel
and/or gas leaks, or if there is explosive material
nearby.
IMPORTANT:
Only start the engine with the air filter and protective
caps fitted. Foreign objects in the inlet line could cause
machine damage. Also make sure that no tools or other
parts have been left next to the engine.
WARNING!
Never start the engine with the valve cover removed.
There is a risk of personal injury.
For engines with turbochargers, the rotating
compressor turbine can in addition cause serious
personal injuries.
Before any work on the electrical system
WARNING!
Always stop the engine first. Then disconnect the
current at the main switches and any external power
supply before working on the electrical system – to
minimize the risk of electrical hazards.
IMPORTANT:
Never disconnect the current using the main switches
when the engine is running or by disconnecting the
battery cables.
The alternator and electronics could be damaged.
Avoid damage to the engine control
module and other electronics
IMPORTANT:
Switch off the main switch before connecting or
disconnecting a connector.
P0024688
Safety Information
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Before welding work
IMPORTANT:
Before any work with electric weld can begin, the
connection to all control units must be disconnected.
After finished welding, re-connect the connection to all
control units before connecting any battery cable.
Before any work on the cooling system
WARNING!
Stop the engine and let it cool before starting work on
the cooling system. Hot fluids and hot surfaces can
cause burns.
Hot coolant under pressure
CAUTION!
Hot coolant can cause burns. Avoid opening the filler
cap for the coolant when the engine is still hot. Steam
or hot coolant can spray out and system pressure is
lost.
Open the filler cap slowly and release the pressure in
the cooling system if the filler cap or valve must be
opened – or if a plug or a coolant hose must be
removed from a hot engine.
Hot oil under pressure
CAUTION!
Hot oil can cause burns. Avoid getting hot oil on the
skin. Ensure that the lubrication system is not
pressurized before starting any work. Never start or
operate the engine without the oil filler cap is on. There
is a risk that hot oil can spray out.
Refueling
WARNING!
There is always a risk of fire and explosion during
refueling. Smoking is forbidden and the engine must
be stopped.
Safety Information
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Proper fuel quality
IMPORTANT:
Always use the fuel recommended by Volvo Penta.
See Technical Data in Operator’s Manual. Other fuel
can damage the engine.
Wrong fuel quality can also lead to higher service
costs.
WARNING!
Risk of personal injury.
Wrong fuel quality in a diesel engine can cause the fuel
control mechanism to bind which can cause the engine
to overspeed!
Legal requirements to use proper fuel
IMPORTANT:
To meet regulatory requirements for certified emission
levels must always recommended fuel according to
Technical Data in the Operator’s Manual be used.
At any leak detection on the fuel system
WARNING!
Wear safety goggles!
Be extremely careful when searching for leaks in the
fuel system high-pressure circuits. There is very high
pressure in the jet from pipes and injectors. The fuel
may penetrate the tissue and cause serious risk of
blood infection (septicemia).
Handling of fuel pipes
IMPORTANT:
High pressure pipes for fuel must not be bent or
straightened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.
Safe handling of batteries
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the batteries.
A spark caused by an incorrectly connected battery
can be enough for the battery to explode with serious
injuries.
Do not touch the connections during start attempts.
Sparking hazard! Do not lean over batteries.
P0024477
P0024488
Safety Information
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Correct polarity of the batteries
IMPORTANT:
Make sure that the positive (+) and negative (–) battery
cables are correctly connected to the corresponding
battery terminals. Wrong connection may cause
severe damage to electrical equipment.
Risks of electrolyte in batteries
WARNING!
Always wear protective goggles when charging or
handling batteries.
Battery electrolyte is highly corrosive.
Rinse immediately with copious amounts of water if the
electrolyte gets in your eyes. Search directly after the
rinsing help by medical staff.
If it comes electrolyte to unprotected skin, wash
immediately with soap and water.
Layout of the battery compartment
IMPORTANT:
Make sure the battery compartment is designed
according to current safety standards.
Cleaning the engine and components
IMPORTANT:
Never use a high pressure washer for cleaning of
engine or engine components.
P0024468
P0024486
Safety Information
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Cleanliness for sensitive components
IMPORTANT:
Observe meticulous cleanliness when handling
system components.
Even minimal amounts of dirt could cause a
breakdown.
Adjustment of the clutch
CAUTION!
Clutch adjustments must be carried out with the engine
stopped.
Safety Information
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Introduction
Check that you heave received the correct
operator’s manual before continuing reading. If
not, please contact your Volvo Penta dealer. Read
the Operator’s Manual carefully and learn to handle the
engine, controls and other equipment in a safe manner
before you start the engine.
For engine designations, refer to Engine. The
designation is stated on the engine plate, refer to
Identification Numbers.
The illustrations in this book may cover several product
types, which means that there may be slight
differences between the illustrations and the
purchased product. This does, however, not affect the
validity of the information and/or instructions in the
manual. Volvo Penta reserves the right to make
alterations to specifications, design features, and
illustrations without prior notice.
At service, software can be updated that affects the
functionality described in this manual.
About this manual
This Operator's Manual contains the information
required for the correct, safe operation and
maintenance of your Volvo Penta engine. Read the
Operator’s manual carefully and learn to handle the
engine and other equipment in a safe manner before
you start the engine.
Warranty
Your new Volvo Penta engine is covered by a limited
warranty, subject to the conditions compiled in the
Warranty Information. Note that AB Volvo Penta’s
liability is limited to the specification in the Warranty
Information (included CD) and Emission Control
System Warranty Statement.
Read the information carefully, as soon as possible
after delivery. It includes important information about
service and maintenance; the owner is responsible for
being familiar with, checking and implementing these.
Otherwise AB Volvo Penta may deny its warranty
obligations in part or in full.
Contact your Volvo Penta dealer if you have not
received the Warranty Information or Service
Book.
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Running in the engine
The engine must be run in during its first 10
operating hours, as follows:
Run the engine in normal operations. However, full
load may not be applied other than for short periods.
Never run the engine for long stretches at constant
speeds during this period.
Higher oil consumption is normal during the first 100–
200 hours of operation. For this reason, check the oil
level more frequently than the normal
recommendation.
When a disengageable clutch is installed, it should be
checked more carefully during the first days.
Adjustments may be necessary to compensate
bedding-in of the friction plates.
Fuel, oils and coolant
Only use the fuels and oils recommended in the
Operator’s Manual, since other grades may cause
malfunctions, increased fuel consumption, and
possibly shorten the life of the engine.
Always change the oil, oil filters, and fuel filter at the
specified maintenance intervals.
Make sure to always use suitable and correctly mixed
coolant.
Future warranty claims related to engine and
accessories may be denied if an unsuitable coolant
has been used, or if the instructions for coolant mixture
have not been followed.
Introduction
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Maintenance and replacement parts
Volvo Penta engines are designed for maximum
reliability and long life and built to withstand a
demanding environment. The engines also are
designed to have a minimal environmental impact.
These qualities will be maintained through regular
servicing and the use of spare parts with the same
quality as genuine Volvo Penta parts. If reliable and
purpose-built parts are not used, your safety, health,
and the machine’s function may be compromised.
Volvo Penta has a world-wide network of authorized
dealers.
The authorized dealers are Volvo Penta product
specialists, and have the accessories, genuine parts,
test equipment and special tools needed for high
quality service and repair work. Always observe the
maintenance intervals in the manual, the complete
Service Protocol can be found at volvopenta.com.
Remember to note the engine / transmission
identification number when you order service and
spare parts.
Excessive strain on a product and
components
Volvo Penta products and components are not
dimensioned for external loads. Never stand or step
onto an engine, transmission or its components. Loads
can bring about damage and the malfunction of a
product or property.
Introduction
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Environmental care
Environmental care is a core value at Volvo Penta.
Energy efficiency and low emissions are among the
most important product related aspects and priority
focus areas for Volvo Penta business. Several of the
global challenges the world faces are directly or
indirectly related to power industries and transports.
We recognize that Volvo Penta is part of the
environmental problems, but we are also convinced
that we are a part of the solution.
Volvo Penta currently has a broad engine program in
which great advances have been made in reducing
exhaust emissions in the same time as the fuel
consumption has been improved. Through regular
maintenance, the Volvo Penta engines retain its low
fuel consumption and low emissions. We hope that you
will be keen to preserve these qualities.
Always follow the directions in the Operator’s Manual
regarding fuel grades, operation and maintenance to
avoid unnecessary environmental impact. Contact
your Volvo Penta dealer if you notice any changes
such as increased fuel consumption or exhaust smoke.
Remember always to hand in environmental
hazardous waste such as drained oil, coolant, old
batteries, etc. for treatment at a recycling facility. Our
united efforts can make a valuable contribution to the
environment.
Introduction
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Certified engines
If you own an emission-certified engine used in an
area where exhaust emissions are regulated by
law, this places special demands on the care and
maintenance you provide your engine.
NOTICE! Neglects or failure to follow the points listed
here may invalidate the engine emission certificate.
This means AB Volvo Penta can no longer guarantee
engine conformity with the certified model. Volvo Penta
is not responsible for damages or costs arising as a
result of this.
•Certification means that an engine type has been
checked and approved by the relevant authority.
The engine manufacturer guarantees that all
engines of the same type are equivalent to the
certified engine.
•It is the responsibility of the operator/user to ensure
that no intentional misuse of the engine takes place.
•Volvo Penta maintenance and service intervals
must be complied with.
•Any case of malfunction must be rectified without
delay.
•Only use genuine Volvo Penta parts or spare parts
with the same quality as genuine Volvo Penta parts.
•Volvo Penta recommends that service to injection
pumps, pump settings and injectors always are
carried out by a qualified workshop.
•The engine must not be converted or modified in any
way, except with accessories and service kits that
Volvo Penta has approved for the engine.
•No installation changes to the exhaust pipe and
engine air inlet ducts may be made.
•No warranty seals (where present on the product)
may be broken by unauthorized persons.
•The general instructions in the Operator's Manual
concerning operation, service and maintenance
apply.
Introduction
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