Volvo TAD734GE User manual

Users guide and maintenance
manual
V
VO OL LV VO O
D
Di ie es se el l e en ng gi in ne e
T
TA AD D7 73 34 4G GE E
E
EM MS S 2 2
7747302 (English03-2007)
33522069101_0_1

TAD734GE
(EMS 2)
OPERATOR’S MANUALp

Engine data
Engine designation ........................... Product number ....................................
Serial number .........................................................................................................
Clutch, type/nr. .......................................................................................................
Nearest Volvo Penta service location
Name .......................................................................... Telephone ....................
Address ...................................................................................................................
© 2007 AB VOLVO PENTA
Volvo reserves the right to make changes
Printed on environmentally friendly paper
Foreword
Volvo Penta industrial engines are relied upon throughout the world,
in both mobile and stationary applications, under some of the most
rigorous conditions imaginable. This is not by chance.
After more than 90 years of producing engines the name Volvo Penta
has come to symbolize reliability, technical ingenuity, first-class perfor-
mance and longevity. We believe that these characteristics are also
ultimately your requirements and expectations for new Volvo Penta
industrial engines.
To make certain that your expectations are matched, we ask that
you read carefully through the instruction book before starting
the engine.
Sincerely
AB VOLVO PENTA

Safety information ................................................. 2
Safety precautions for operation
and maintenance.................................................. 3
Introduction ........................................................... 6
Environmental care ............................................... 6
Running in ............................................................. 6
Fuel and oils ......................................................... 6
Maintenance and spare parts ................................ 6
Certified engines ................................................... 7
Warranty ................................................................ 7
Presentation .......................................................... 8
Technical description ............................................ 8
Identification numbers ........................................... 9
Component location ............................................. 10
Location of sensors.............................................. 11
EMS 2 ................................................................ 12
Instrument, EMS 2 ............................................... 13
DCU (Display Control Unit) ................................... 14
Starting the engine.............................................. 20
Before starting ................................................... 20
Start routine (DCU) ............................................. 21
Starting in extreme cold ..................................... 22
Never use start spray ......................................... 23
Starting with auxiliary batteries .......................... 23
Running ............................................................... 24
Check Gauges ................................................... 24
Fault indication................................................... 24
Operation at low load ......................................... 24
Stopping the engine ........................................... 25
Before stopping .................................................. 25
Stop ................................................................... 25
After stopping .................................................... 25
Auxiliary stop ...................................................... 25
Maintenance schedule ........................................ 26
Maintenance ........................................................ 28
Engine, general ................................................... 28
Lubrication system ............................................... 30
Cooling system ................................................... 33
Fuel system ........................................................ 38
Electrical system ................................................ 41
Shutdown ............................................................ 44
Preservation ........................................................ 44
Restoration ......................................................... 45
Troubleshooting.................................................. 46
Diagnostic function ............................................. 47
Fault notification ................................................. 47
Effect on the engine ............................................ 47
Operation ............................................................ 48
Reading fault codes ............................................ 48
Fault codes .......................................................... 50
Technical data ..................................................... 59
General ............................................................... 59
Lubrication system .............................................. 60
Fuel system ........................................................ 60
Cooling system ................................................... 61
Electrical system ................................................ 61
Table of contents

2
Safety information
Incorrect operation can lead to personal injury and damage to products or property. Therefore
read through the instruction book very carefully before you start the engine or do any mainte-
nance or servicework. If there is still something which is unclear or you are unsure of, please
contact your Volvo Penta dealer for assistance.
This symbol is used in the instruction book and on the product, to call your attention
to the fact that this is safety information. Always read such information very carefully.
Safety texts in the instruction book have the following order of priority:
WARNING! Warns for the risk of personal injury, major damage to product or property, or
serious malfunctions if the instruction is ignored.
IMPORTANT! Is used to call attention to things which could cause damage or malfunctions
to product or property.
NOTE! Used to draw your attention to important information that will facilitate the work or
operation in progress.
This symbol is used on our products in some cases and refers to important information in
the instruction book. Make sure that warning and information symbols on the engine are clearly
visible and legible. Replace symbols which have been damaged or painted over.
Read this chapter very carefully. It has to do with your safety. It describes how safety information is presented in
the instruction book and on the product. It also gives you an overview of the basic safety precautions for maintain-
ing the engine.
Check that you have received the correct operator’s manual before you read on. If not, please contact your
Volvo Penta dealer.

Safety information
3
Safety precautions for operation and maintenance
Daily Checks
Make a habit of always checking the engine compart-
ment before running (before the engine is started)
and after running (when the engine has been
stopped). This helps you to quickly discover whether
any leakage of fuel, coolant, oil or any other abnormal
event has happened, or is about to happen.
Fuel Filling
There is always a risk of fire and explosion when refu-
eling. Smoking is forbidden, and the engine must be
stopped.
Never over-fill the tank. Close the tank cap securely.
Only use the fuel recommended in the instruction
book. The wrong grade of fuel can cause malfunctions
or stop the engine. In a diesel engine, it can also
cause the injection pump to bind and the engine to
over-rev, entailing a strong risk of personal injury and
machinery damage.
Carbon Monoxide Poisoning
Only start the engine in a well-ventilated area. When
running in a confined space, exhaust fumes and
crankcase gases must be led away.
Operation
The engine must not be operated in environments
which contain explosive media since none of the elec-
trical and mechanical components are spark proof.
Approaching a running engine is a safetyrisk. Hair, fin-
gers, loose clothes, or dropped tools can catch on ro-
tating components and cause severe injury.
When engines are supplied without touch guards, all
rotating components and hot surfaces must be pro-
tected after installation in their application, if neces-
sary for personal safety.
Ignition Lock
If the instrument panel does not have a key switch,
the engine compartment must be lockable, to prevent
unauthorized persons from starting the engine. Alter-
natively, a lockable main switch can be used.
Maintance and Service
Proficiency
The instruction book contains directions on how to
carry out the most common service and maintenance
tasks safely and correctly. Read them carefully before
starting work.
Literature for more major tasks is available from your
Volvo Penta dealer.
Never do a job if you are not entirely sure about how
to do it. Please contact your Volvo Penta dealer and
ask for assistance instead.
Stop the Engine
Stop the engine before opening or removing the en-
gine hatch/hood. Maintenance and service should be
done with the engine stopped, unless otherwise speci-
fied.
Prevent the engine from being started by pulling out
the starter key and cutting the current with the main
switch. Lock them in the off position. Fix a notice by
the operator’s station to say that work is in progress.
Working with, or approaching a running engine is a
safety risk. Hair, fingers, loose clothes, or dropped
tools can catch on rotating components and cause se-
vere injury. Volvo Penta recommends that all service
work which requires the engine to be running should
be done by an authorized Volvo Penta workshop.

Safety information
4
Removing the Engine
When removing the engine the lifting rings mounted on
the engine should be used. Always check that the lift-
ing devices are in good condition and that they have
the correct capacity for the lift (engine weight together
with auxiliaries, if fitted). The engine should be raised
with an adjustable lifting boom for safe handling. All
chains or cables should be parallel to each other and
should be as square as possible to the top of the en-
gine. Note that auxiliary equipment installed on the en-
gine may change its center of gravity. Special lifting
devices may then be needed to obtain a correct bal-
ance for safe handling. Never carry out work on an en-
gine that is only suspended in a hoist.
Before Starting
Re-install all guards which have been removed during
service work, before re-starting the engine. Make sure
that there are no tools or other objects left behind on
the engine.
Never start a turbocharged engine without the air filter
in place. The rotating compressor turbine in the turbo-
charger can cause severe injury. There is also a risk
that foreign bodies could be sucked in and cause ma-
chinery damage.
Fire and Explosion
Fuel and Lubricating Oil
All fuel, most lubricants and many chemicals are
flammable. Always read and follow the directions on
the packages.
Work on the fuel system must be done with the en-
gine cold. Fuel leakages and spills on hot surfaces or
electrical components can cause fires.
Store oil and fuel-soaked rags and other flammable
material in such a way that there is no danger of them
causing fire. In certain circumstances oil-soaked rags
can spontaneously ignite.
Never smoke when filling fuel, lubricating oil or when
in the vicinity of fueling stations or the engine bay.
Non-original Spare Parts
Components in fuel systems and electrical systems
on Volvo Penta engines are designed and manufac-
tured to minimize the risk of explosions and fire, in ac-
cordance with applicable legal requirements.
The use of non-original spare parts can cause an ex-
plosion or fire.
Batteries
Batteries contain and give off oxyhydrogen, especially
when charged. This gas is very flammable and highly
explosive.
Smoking, naked flames or sparks must never occur in
the vicinity of batteries or the battery compartment.
Incorrect connection of a battery cable or start cable
can cause a spark which can in turn be sufficient to
cause the battery to explode.
Start Spray
Never use start spray or similar preparations as a
start aid on engines with air pre-heating (glow plugs/
starting heater). They may cause an explosion in the
inlet manifold. Danger of personal injury.
Safety precautions for operation and maintenance (contd.)

Safety information
5
Hot Surfaces and Fluids
A hot engine always presents the risk of burns. Be on
your guard against hot surfaces: the exhaust mani-
fold, turbocharger, oil pan, charge air pipe, starting
heater, hot coolant and hot lubricating oil in pipes,
hoses etc.
Chemicals
Most chemicals, such as glycol, rust preventer, con-
servation oils, degreasers etc. are hazardous. Always
read and follow the directions on the packages.
Certain chemicals such as preservative oils are flam-
mable and also dangerous when inhaled. Ensure good
ventilation and use a protective mask when spraying.
Always read and follow the directions on the packages.
Keep chemicals and other hazardous materials out of
the reach of children. Hand in surplus or used chemi-
cals to a recycling station for disposal.
Lubrication System
Hot oil can cause burns. Avoid skin contact with hot
oil. Make sure that the oil system is de-pressurized
before starting work. Never start or run the engine with
the oil filler cap removed, because of the risk of oil
ejection.
Cooling System
Avoid opening the coolant filling cap when the engine
is hot. Steam or hot coolant can spray out and cause
burns.
Nevertheless, if the filler cap, coolant hose etc., has
to be opened or removed when the engine is hot, undo
the filler cap slowly and carefully, to release the pres-
sure before removing the filler cap completely and
starting work. Note that the coolant can still be hot
and cause burns.
Fuel System
Always protect your hands when searching for leaks.
Fluids which leak under pressure can force their way
into body tissue and cause severe injury. There is a
risk of blood poisoning (septicemia).
Always cover the alternator if it is located beneath the
fuel filters. Fuel spillage can damage the alternator.
Electrical system
Cut the Current
Before any work is done on the electrical system, the
engine must be stopped and the current cut by switch-
ing off the main switch(es). External current supply for
engine heaters, battery chargers or other auxiliary
equipment connected to the engine must be discon-
nected.
Batteries
Batteries contain a highly corrosive electrolyte. Pro-
tect your eyes, skin and clothes when handling or
charging batteries. Always use protective goggles and
gloves.
If acid comes into contact with your skin, wash with
soap and plenty of water. If you get battery acid in
your eyes, flush at once with lots of cold water, and
seek medical assistance immediately.
Arc Welding
Remove the positive and negative cables from the
batteries. Then disconnect all cables connected to the
alternator.
Always connect the welder earth clamp to the compo-
nent to be welded, and as close as possible to the
weld site. The clamp must never be connected to the
engine or in such a way that current can pass through
a bearing.
When welding is completed: Always connect the al-
ternator cables before the battery cables are re-at-
tached.

6
Introduction
This instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta industrial
engine. It contains the information you need to be able to operate and maintain the engine in a safe and propper
manner. Read the instruction book carefully and learn how to operate the engine, controls and other equipment in
a safe manner before you start the engine.
Environmental care
All of us want to live in a clean, healthy environment,
where we can breathe clean air, see healthy trees,
have clean water in lakes and seas, and be able to
enjoy sunshine without fearing for our health. Unfortu-
nately, this cannot be taken for granted these days; it
is something all of us must work toward.
As an engine manufacturer, Volvo Penta has particular
responsibility and for this reason, environmental care is
an obvious foundation of our product development. Vol-
vo Penta currently has a broad range of engines where
great progress has been made in the reduction of em-
misions, fuel-consumption and engine noise etc.
We hope that you will take care to maintain these
qualities. Always follow the directions in the instruc-
tion book regarding fuel grades, operation and mainte-
nance, to avoid unnecessary environmental impact.
Please contact your Volvo Penta dealer if you notice
any changes such as increased fuel consumption or
increased exhaust smoke.
Always remember to hand in hazardous waste such
as drained oil, coolant, old batteries etc. for disposal
at a recycling facility.
Through our common efforts, we can together make a
valuable contribution to the environment.
Running in
The engine must be “run in” during its first 10
running hours, in accordance with the following:
Use the engine in normal operation. Full load should
only be applied for short periods. Never run the engine
at constant revolutions for prolonged periods during
running in.
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 reccomendation.
When an disengageable clutch is installed, this should
be checked more carefully during the first days. Ad-
justments may need to be done to compensate bed-
ding-in of the friction plates.
Fuel and Oils
Only use the grades of fuels and oils recommended in
the instruction book (refer to the “Maintenance” chapter
under the fuel and lubrication system headings). Other
grades of fuel and oils can cause malfunctions, increased
fuel consumption and over time even shorten the life of
the engine.
Always change the oil, oil filter and fuel filter according
to the prescribed intervals.
Maintenance and Spare Parts
Volvo Penta engines are designed for maximum reli-
ability and long life. They are built to withstand a de-
manding environment, but also to have the smallest
possible environmental impact. Regular maintenance
and the use of Volvo Penta original spare parts will
ensure these qualities are retained.
Volvo Penta has a world-wide network of authorized
dealers. They are Volvo Penta product specialists,
and have the accessories, original spares, test equip-
ment and special tools necessary for high quality ser-
vice and repair work.
Always comply with the maintenance schedule in
the instruction book, and remember to note the
engine/transmission identification number when
you order service and spare parts.
IMPORTANT! This instruction book describes the engine and equipment as offered for sale by Volvo Penta.
Variations in appearance and function of the controls and instruments may occur in certain variants. In these
cases, refer to the operator’s manual for the relevant application.