Information about Volvo Engine TAD734GE The DU is an computerized instrument panel which shows engine working values on an LCD screen. In the display it is possible to show multiple windows with different information, i. g. Volvo engine rpm, coolant temperature, fuel consumption and fault messages. At start up, the display performs a self-test. If an constant signal is heard, the system has discovered a malfunction. The display will work but may act in an unexpected way. The DU is connected between the engine control unit and the CIU or DCU. Contrast In the display modes Engine, Trip and Graph, it is possible to adjust the contrast. Press button 5 outside the menu and then + (button 4) or - (button 3) to adjust the contrast. Contrast.jpg Engine Rpm and coolant temperature is shown in the upper part of the display. In the lower part it will show trip computer and a fuel level indicator, if these functions are installed. Coolant.jpg Multi In the multi mode, button 2, the information can be shown in four windows, analogue or digital. The display toggles between the two when button 2 is pressed repeatedly. By pressing button 5, the right arrow, you choose what information to be shown in the different windows. Press repeatedly on the button that correspond to the window, until desired information is shown. Multi.jpg Trip To 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 a beep is heard. Trip.jpg Graph The information is shown as graphs. Press button 4 repeatedly 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 line in the display. Graph.jpg Configuration menu Press button 5 for three seconds to enter the Configuration menu. Navigate with the up and down arrows, select with the right arrow. Configuration menu.jpg Units - PRESSURE: kPa, PS - VOLUME; LITRE, GAL, Imperial GAL. Fuel rate is adjusted according to volume unit, L/H, GAL/H, IGAL/H. - TEMPERATURE; °C, °F Units.jpg Alarm Status List of active alarms, refer to Reading fault codes via the DU (Display Unit) Alarm status.jpg Settings LANGUAGE; setting of what language is to be used in the display. BLEEP; On/Off, setting if pressing the instrument buttons will be followed by a beep or not. DISPLAY; setting of ENGINE RPM gauges RPM ENGINE, 2500-9000 RPM, in steps of 500 RPM GRAPH RANGE, 2 minutes- 8 hours in the following steps, 2MINS, 10MINS, 30MINS, 60MINS, 2HRS, 4HRS, 8HRS Setings.jpg SYSTEM DEMO, switches the DEMO mode ON/OFF RESTORE DEAFAULTS, reset all configuration to default values. COM VIEWER, displays latest message on communication ports PROG TX, transfers content of the application on Flash memory to other CAN units on the same CAN bus. ABOUT, displays ID NO - display serial number EEPROM - number of write on EEPROM VERS - software version number CHK - Flash memory checksum PART No - Volvo software part number SOURCE - source of received data LABEL - Allocated Label on the same bus System.jpg CIU (Control Interface Unit) The CIU is a "translator" between the control unit (EMS) and the customer's own control panel. The CIU has two serial communication links, one fast and one slow. The fast one is a so-called CAN link. All data related to instruments, indication lamps, connectors and potentiometers is controlled by this link. The slow link manages diagnostic information for flashing codes etc. Control Interface Unit.jpg Easy Link Instruments The following Easy Link instruments are available - Tachometer / hours counter (fault codes are also displayed on the tachometer display when the diagnostic button is pressed) - Coolant temperature - Oil pressure - Oiltemperature - Batteryvoltage - Alarm panel - Turbo pressure DCU (Display Control Unit) The pre-heating time is adjusted to suit engine temperature, and may last up to 50 seconds both before and after starting. The starter motor connection time is maximized to 20 seconds. After that, the starter motor circuit is cut for 80 seconds to protect the starter motor against overheating. NOTICE! Preheat must be activated when the temperature is below o °C (32°F) DCU.jpg With preheating 1 Press the ON/OFF button (6) 2 Press the SEL button (7) to come to the main menu 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 active please wait" is shown in the display. 5 Wait until the text disappears and then press the START 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)
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Volvo Diesel Engine Arrangement Locations below ground level Locations below ground level must have sufficient capacity to support the weight of the entire installation plus the concrete foundation it is to rest on. If there is doubt regarding the supporting capacity of the location below ground level where the foundation is to stand, a qualified technician must be contacted to determine the type and size of the concrete foundation Fixed concrete block The fixed concrete block is a proven method and for certain installations the most suitable. In these cases the generator set's underframe is bolted directly to the concrete block. Concrete block size is recommended to extend 400–500 mm (16–20") beyond each side of the assembled generator set. The surface of the block is usually above bed level so that the difference “h” is 100-200 mm (4–8") and forms a pedestal. After the concrete depth required for installation weight and stability has been determined, check that the ground is able to bear the total weight (engine plus concrete block) and withstand the forces concerned. It may not be possible to reach a firm ground layer, e.g. hard clay, compacted sand and gravel or rock, without digging unreasonably deeply. In such a situation the load must be spread over a large area on a concrete slab. Floating concrete block A floating concrete block is an effective alternative to a fixed concrete block. In order to determine the size of the concrete block, apply the same calculation as for a fixed concrete block. The block is cast beforehand in a wooden mold. There must be an air gap of approximately 25 mm (1") around all four block sides. The gap at ground level must be sealed with a non-bonding material to keep out dirt and water, but nevertheless also provide flexibility. Place watertight insulation material beneath the floating block. This insulates the generator set and the block, and significantly reduces vibrations to the surroundings. All equipment connected to the generator set, e.g. exhaust systems and fuel pipes, must be installed with flexible connections. Installation procedure on concrete blocks When the concrete block is poured, recesses must be made for the mounting bolts i.e. anchors or similar. Place removable wooden boxes at each mounting bolt location. The size of the box must be adapted to the size of the bolt used for installation. Remove the boxes when the concrete has almost cured. Make sure the upper surface of the concrete block is fairly even and fault free. The illustration shows the method with a normal anchor bolt. The depth d must be slightly greater than bolt length L. This is so that the bolt can be dropped into the hole for the grouting, and so that the installation can be rolled into place without the bolts being in the way. Install a steel packing plate at each mounting point above the hole and on each side of the bolt. Fixed mounts Fixed mounts are normally used on engines installed on a frame as illustrated. The driven unit may be a generator, a water pump or a compressor. Vibration insulating mounts In order to reduce noise levels and absorb vibrations transferred to the installation foundation, the frame is equipped with flexible mounts as illustrated. The flexible mounts must be placed so that the load is distributed evenly. The location of the mounts is determined by calculating the total weight and center of gravity of the installation, then the mounts are arranging evenly around the unit's center of gravity. The number of flexible mounts is normally between 4 and 6. It is important to know the Volvo engine's critical rpm and the load that will be operated at the intended installation so that the correct flexible mount hardness and layout is chosen. To be noted when selecting flexible mounts On the whole, a flexible mount is preferable to other configurations. A flexible mount is optimally designed if the natural frequency from the vibration system, of which the engine and mount elasticity form part, is at least 40 % lower than the engine's lowest occurring frequency. A low natural frequency requires soft flexible mounts. However, such mounts have the disadvantage of allowing significant deflection from external forces that may occur with inclined installations or shock loads. On 4 cylinder engines it is practically impossible to install a fixed connection between the engine and the underframe when taking into consideration impulse forces of the second order. A prerequisite for correct flexible mounts is that the foundation must be significantly stiffer than the flexible elements, otherwise the foundation would act as a extra spring. The elements must be arranged so that they bend when they are affected by the forces that arise during operations. There must be sufficient free movement between the engine and the chassis. Flexible mounts that fit Volvo Penta engines can be found under “Order specification-optional equipment” in the Sales Support Tool, Partner Network for each engine type. In order to withstand vibrational deflections from the flexible attachment, all pipes, cables and lines must also be of flexible design. Rubber mounted radiators are acceptable if the engine is mounted fixed. (If both the engine and the radiator are flexibly mounted, there is a risk of the fan coming into contact with the fan ring). When the engine, or the engine and transmission, is installed on the flexible mounts, make sure that the underframe is level, parallel and even. Also make sure that the mount hole patterns are correct and the holes sufficiently large in order to avoid uneven load stress and twisting of the mounts. Twisted rubber mounts affect sound dampening and vibration characteristics negatively and drastically shorten the service life of the rubber. Volvo TAD734GE Diesel Engine Operating Manual This Operator's Manual concerns the Volvo TAD734GE engine, an inline 6-cylinder direct-injection diesel engine. The engine is equipped with a common rail fuel injection system, IEGR (internal exhaust gas re-circulation), electronically- controlled fuel management (EMS 2), a turbocharger, a thermostatically-controlled cooling system and electronic speed control. Presentation EMS (Engine Management System) EMS is an electronic system with CAN communication (Controller Area Network) for diesel engine control. The system was developed by Volvo and includes fuel control and a diagnostic function. Summary The system comprises such items as a control unit, sensors and injectors. The sensors send input signals to the control unit, which in turn controls the injectors. The information from the sensors gives exact data about prevailing operating conditions and allows the processor in the control module to calculate the correct injection amount, injection timing and check engine health. Input signals The control unit receives input signals about engine operating conditions from the following components - coolant temperature sensor - charge air pressure and temperature sensor - rpm sensor, camshaft - rpm sensor, flywheel - coolant level sensor - oil pressure sensor - fuel pressure sensor - water-in-fuel indicator - fuel pressure in distributor manifold Output signals The control module uses the input signals to control the following components: - unitinjectors - starter motor - main relay - pre-heating relay MPROP, high pressure fuel pump Fuel control The engine fuel requirement is analyzed up to 100 times per second. The amount of fuel injected into the engine and the injection advance are fully electronically controlled via fuel valves on the unit injectors. This means that the engine always receives the correct volume of fuel in all operating conditions, which provides lower fuel consumption and minimal exhaust emissions etc. Diagnostic Function The task of the diagnostic function is to detect and locate disturbances within the EMS 2 system, to protect the engine, and to provide information about problems that arise. If a malfunction is detected, it is announced by warning lamps, a flashing diagnostic lamp or in plain language on the instrument panel, depending on the equipment used. If a fault code is obtained as a flashing code or in plain language, it is used for guidance in any fault tracing. Fault codes can also be read by the Volvo VODIA tool at authorized Volvo Penta workshops. If there is a serious malfunction, the engine will shut down altogether, or the control unit will reduce the power output (depending on application). Here too, a fault code is set for guidance in any fault tracing. Instruments and Controls Display Control Unit The DCU control panel is available as an optional accessory for the EMS (Engine Management System) electronic control system. The DCU is a digital instrument panel which communicates with the Volvo engine control unit. The DCU has 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 different functions in the EMS system. NOTICE! Settings and what engine data that appears in the display may vary depending on installation and engine model. NOTICE! The menus and illustrations shown here are the English version. The language can be changed, however; refer to the Setup menu. Start When the DCU panel is started, the "Engine Data" menu is displayed; press "ESC" to come to the main menu. 1 LED display 2 START. Starts the engine 3 SPEED - . Reduces engine rpm 4 SPEED +. Increases engine rpm 5 STOP. Stops the engine 6 ON/OFF. Starts and stops the system 7 Scroll downwards in menus 8 SEL. Selects in menus 9 Scroll upwards in menus 10 ESC. Return to previous menu selection Menus There are several sub-menus under each main menu. There is not space for all the menu choices on the display. To scroll through the menus, use the 7 and 9 buttons on the display. Press the SEL button 8 to make a selection. Refer to the illustration on the previous page. NOTICE! The Setup menu can be used to select the language that you want to use on the display. Main menu Engine data, current engine data Preheat, manual activation of pre-heating. Must be activated 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 the engine and DCU data Checking signal Cable Rail Pressure Sensor of Volvo Engine Tools: 885675 Break-out cable 88890074 Multimeter 1 Cut the current with the main switch. 2 Disconnect the connector from the sensor. 3 Connect break-out cable 885675 to the cable harness connector to the engine control unit. 4 Use multimeter 88890074 to do resistance measurement against the engine control unit. NOTICE! Measurement is done to eliminate short circuiting or breaks in the cable to the engine control unit. Checking injection control pressure sensor Tools: 885675 Break-out cable 88890074 Multimeter 1 Turn ignition off. 2 Disconnect the connector from the sensor. 3 Connect break-out cable 885675 between the sensor and the engine control unit. 4 Use multimeter 88890074 for voltage measurement. 5 Turn ignition on. Checking the wiring to the MPROP valve Tools: 88890074 Multimeter NOTICE! If any of the measurements shows an abnormal value, check the wiring to and from the Volvo engine interface. 1 Cut the current with the main switch. 2 Remove the connector to the MPROP. 3 Remove connector A from the EMS2. 4 Use multimeter 88890074 to do a resistance measurement against the engine control unit connector A. Checking the solenoid in the MPROP valve Tools: 885675 Break-out cable 88890074 Multimeter 1 Cut the current with the main switch. 2 Remove the connector from the MPROP valve. Connect break-out cable 885675 to the valve. NOTICE! Do not connect the other end of the adapter cable to the engine cable harness, since this can cause a measurement error. 3 Use multimeter 88890074 to check the resistance in the solenoid in the MPROP valve. NOTICE! Measurement is done to eliminate short circuiting or breaks in the MPROP valve. VODIA Log Parameters Logging throttle signal with Vodia To verify the throttle signal on the J1587 bus do as follow: 1 Choose “Log test” under the “Service and maintenance”meny. 2 Choose “MID 128, Accelerator Pedal Position” and “MID 144, Throttle Calibrated Position” and press play. 3 Verify that booth throttle values displayed in percentage by Vodia changes simultaneous while moving the throttle. Volvo Penta TDTAD Series Engine Data
Lubrication System Oil change intervals can vary between 150 and 500 hours depending on the quality of the lubricant and the sulphur content of the fuel. Note that the oil change interval should never be longer than 12 months. If longer intervals are required than those stated in the table below, the condition of the oil must be tested regularly by the oil manufacturer. 1) If sulphur content is > 1.0% by weight, use oil with TBN > 15. 2) Lowest recommended oil type, engine oil of an higher type can always be used. 3) API: CG-4 or CH-4 are acceptable in markets outside Europe, instead of ACEA E3. Viscosity Select the viscosity according to the table. The temperature values refer to stable ambient temperatures. * SAE 5W/30 refers to synthetic or semi-synthetic oils. Fuel System Fuel specification Fuel must comply with national and international standards for commercially supplied fuels. NOTICE! Bio-diesel according to EN 14214, kerosene and light fuel oil may not be used. The following fuel standards are approved: EN 590 (with nationally adapted environmental and cold weather requirements) ASTM D 975 No 1-D and 2-D JIS KK 2204 (may only be used if lubricity corresponds to EN 590) Sulfur content: According to current national legislation. If the sulfur content exceeds 0.5 weight-percent, the oil change intervals must be amended; Extremely low sulfur content fuel (EC1 diesel in Sweden and city diesel in Finland) can cause a loss of up to 5% of power and an increase in fuel consumption of about 2–3 %. General fuel requirements The fuel quality is essential for engine function, durability and emission compliance. Only fuels meeting relevant legal requirements and national and international standards shall be used; such as European EN590 diesel and North American ASTM D975 diesel. Usage of fuels or fuel blends that do not comply with the below specifications given in this document is not allowed and Volvo Penta will not accept warranty in case of fuel related engine damages. Diesel fuel requirements An insufficient cetane number (“ignitability”) leads to poor startability and increased exhaust emissions. Requirement; cetane number min 45. 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 increase emissions and give engine corrosion and wear. Requirement; The max allowed sulfur content is5000 ppm, with the restriction that oil of quality VDS 3 must be used for sulfur content above 3000 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) can cause 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) and the CFPP (cold filter plugging point). The oil companies are always responsible for providing fuels with the correct cold flow properties for any time of the year. FAME (“biodiesel”) Requirement;The max allowed FAME content is 30%, if the FAME part complies with EN14214 and the diesel complies with EN590, with specific service requirements as below: • Oil change and oil-filter replacement intervals must be halved. • Fuel filters shall be changed at every oil change and fuel filter housings and seals shall be changed annually. • A fuel heater should be used due to the high viscosity of FAME at low temperature. In order to avoid starting problems FAME should not be used below -10°C. • A fuel filter with water separator must be used since FAME is hygroscopic. • When shifting from regular diesel fuel to higher FAME content the fuel tank must be cleaned and the fuel filter must be replaced after 50 h. • If the engine has not been used for a period over 4 weeks the tank and fuel system must be flushed clean by running the engine on at least one full tank of regular diesel. NOTICE! Engines for emergency applications, e.g. standby genset , may only run with market diesel fuel with minimum FAME content. Paraffinic fuels (“Synthetic Diesel”) - HVO and GTL HVO (Hydro-treated Vegetable Oil) are renewable, and GTL (Gas-To-Liquid) are fossil, paraffinic fuels. Usage of paraffinic 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 and GTL 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! Kerosene F-63 can be used, but Volvo Penta does not guarantee emission compliance. F-34/JP8 and F-44/JP5 can also be used, but only with lubricity additives to ensure max 520 μm wear scar in the HFRR test (ISO 12156). Additives The 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 alcohol into the fuel tank. 1) The coolant volumes listed apply to the use of Volvo Penta original coolants 2) engine only Coolant Volvo 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 each other. Identification Numbers Engine Designation The following information can be read from the engine designation: T = Turbocharger 3 = Generation A = Air-to-air charge air cooler (CAC) 1 = Version W = Water-to-air charge air cooler (CAC) V = Engine for stationary and mobile application D = Diesel engines G = Generating Set Engines 10 = Cylinder displacement, liters E = Emisson certified engine Volvo Generator Introduction--Volvo Diesel Engine Starlight Volvo series diesel generator is powered by renowned electric-fuel-injection diesel engine, comply with EURO II or EURO III and EPA standard for exhaust emission. The global-famous Swedish VOLVO was establish in 1927. its strong brands have long been linked with its three core values: quality, safety and care of the environment. Volvo Penta, one of the subordinates of VOLVO group is expert at production of power generating engine, vechicle engine, and marine engine. The technologies of six-cylinder and electronic injection outdisance other competitors, enjoying advantages as small volume, fuel-saving, high precision, long operating life. The high-quality products have won favorable comments from customers home and abroad. Volvo Generator Advantages Volvo generator engines adopt full electronic fuel injection control technology, with high performance and high reliability. They have the merits of good startup performance, voltage stability, reliable operation, low emissions, low noise, convenient maintenance, good efficiency and good ability to adapt the plateau.Starlight Volvo series diesel gensets officially authorized products of the Volvo company. With better performance, better quality and more guaranteed services compared with similar products, they are products recommended by the Starlight Volvo Genset Department. Introduction of Volvo company Volvo company is Sweden's largest industrial enterpriseswith a history of 120 years, and it is one of the world's oldest engine manufacturers.So far its engine production has reached more than 1 million sets, and they have been widely applied in power section of automobile, engineering machinery and ships. They are even the ideal for power gensets.VOLVO company, at the same time, is the only manufacturer in the world to focus on inline four-cylinder and six-cylinder diesel engines, and it is in a leading position on this technology. VOLVO generator series are imported with original packaging, with a full set of certificate of origin, certificate of approval, inspection certificate, customs declaration certificate, etc. As VOLVO’s OEM partner, our company has provided hundreds of high-performance gensets for domestic users. Characteristics of Volvo Diesel Engines 1. High ability to withstand the load and fast, reliable cold start performance, low resistance supercharger and responsive injection system lead to a high resistance to load of the engine in a very short recovering time; 2. The heater is installed in the intake manifold, making it easier for the engine to start at a low temperature. 3. Stable working, low noise, optimized design of damping body, accurate matching of turbocharger amd low-speed cooling fan. Less emissions, low operating cost, typical exhaust smoke less than 1 Bosch units; 4. Low fuel consumption 5. Small and exquisite: delicate and exquisite appearance design compared with other products. 6. Real international applicable parts with global recognition and global service network. Sweden Volvo have set up large center for maintenance, training and spare parts distribution in China. Characteristics of Volvo Diesel Generator Sets 1. Power range:68KW—550KW 2. Strong ability to withstand load 3. Smooth operation and low noise of Engine 4. Fast and reliable coldstart performance 5. Delicate and exquisite appearance design 6. Small fuel consumption, low operating cost 7. Less emissions, economic and environmental protection 8. Service network all over the world, plenty of spare parts supply Volvo Generator Supply Standard Configuration 1. Warranty card of original factory for Diesel engine (with all accessories, three-filters, electrical system), 2. Manual of brushless AC generator 3. Steel structure base Engine operation manual 4. Fan radiator cooling system Generator operation manual 5. Flange connecting shaft Test report of sets 6, 24V start motor and charging motor Diesel gensets 7. Air filter, diesel filter, oil filter Product certificate 8. Airborne type control panel 9. MCCB air protection switch 10. 24v start-up battery and battery line 11. Shock absorber of sets 12. Efficient industrial muffler 13. Random technical documents Installation of Volvo Generators 1. Choice of Volvo generator chamber 1) Volvo diesel gensets require that surrounding environment is conducive to the ventilation and exhaust 2) Enough operation space 3) Reasonable layout 4) Cannot place flammable items 2. Installation basis of Volvo gensets 1) As long as the ground has enough bearing capacity, the foundation platform is not needed 2) Volvo diesel gensets adopt effective shock absorbing device, and foundation need no isolation treatment 3) For the size of the foundation platform, please refer to the "Installation Manual" 4) No anchor bolt should be reserved for the foundation platform 3. Cooling and ventilation system of Volvo gensets 1) Standard Volvo diesel gensets use the closed cooling water cycle system 2) Due to chamber conditions, we may adopt fission type cooling system or heat exchanger system 3) Air inlet and outlet should be in reasonable layout, avoiding heating reflux 4) Air inlet and outlet should be meet the minimum clearance requirements 4. Fuel supply system of Volvo gensets 1) GF series Volvo diesel gensets need to be equipped with daily tank additionally 2) The height difference between the tank and the unit meets the requirements 3) The oil taking and returning pipe should meet the size requirement 4) The oil supply system is installed in line with the fire code 5) When the fuel is in poor quality, the installation of a oil-water separator is recommended 5. Exhaust system of Volvo diesel gensets 1) Volvo diesel gensets are equipped with an industrial muffler according to the standard 2) The exhaust system should reduce the quantity of elbow and shorten the total length of the exhaust pipe as far as possible 3) When the length and the quantity of elbow is beyond standard, we should make an appropriate increase in the exhaust pipe diameter 4) The bellows shall be installed between the exhaust pipes and the sets for the purpose of isolation General Information of Volvo Penta Engine Drive belts, checking and adjusting of Volvo Penta Engine Inspection and adjustment should be carried out after running the engine when the belts are warm. Undo the screws (A) before tensioning the generator belts. It should be possible to depress the belts 10 mm between the pulleys. Worn belts which work in pairs should be replaced at the same time. The fan belts have an automatic belt tensioner and do not need adjusting. However, the condition of the belts must be checked. Replace if required. Idling speed, adjustment First check that the air filter is not clogged and that the throttle arm (1) on the fuel injection pump is against the idling speed stop (2) when the throttle mechanism is in idling position. Check also that the throttle arm presses against the max stop (3) when the throttle control is in the wide open throttle (WOT) position. Adjust the control if necessary. Idling speed must only be checked and adjusted when the engine has reached normal operating temperature. For the correct idling speed, see chapter Engines. WARNING! Working with or approaching a running engine is a safety risk. Watch out for rotating components and hot surfaces. RSV governor 1. Allow the engine to operate at low idling speed. 2. If necessary, adjust the engine speed by removing the domed nut (1), slackening off the locknut (2) and adjusting the engine speed with the screw (3). If the engine speed is uneven, the idle speed damping should be adjusted as follows: 1. Remove the domed nut (4) and slacken off the locknut (5). Carefully turn the damping screw (6) clockwise until the engine speed stabilises. 2. Check that the high idling speed has not changed. If it has changed, the damping screw (6) has been screwed in too far. 3. Lock the damping screw (6) and install the domed nut (4) when the adjustment is complete. RQV, RQ governor 1. Allow the engine to operate at low idling speed. 2. If necessary, adjust the engine speed with the screw for low idling speed (1). GAC governor To adjust the idling speed on Generating set engines with GAC governor, refer to the separate documentation supplied with the GAC equipment. Governor (Heinzmann) The governors of the T(A)D 420–731 GE series engines are mechanical variable-speed governors with centrifugal measuring element of M/s Heinzmann. All governor settings may only be conducted by trained specialists on a specifically laid out governor test bench. Engine Fuel Filter Replacement IMPORTANT Cleanliness! No dirt or contaminants may enter the fuel injection system. 1. Remove the filters. 2. Moisten the new filter gasket with a little oil. Screw the filter into place by hand until the gasket touches. And then a further half turn but no more! Bleed fuel system. NOTICE! Take the old filter to a suitable disposal point. 3. Start the engine and check for leaks. Then pump a further 15–20 times. Check for leaks. NOTICE! For engines equipped with a fuel shut-off valve, the fuel injection pump often requires venting as well. This is done by slackening off the fuel injection pump pressure equaliser (3) (27 mm narrow U wrench). Pump with hand pump (2) until fuel containing no air flows out. Engines 420–733: Open the air-venting plug in the overflow valve. (See fig.) Crank the engine on the starter motor or use the manual feedpump (optional equip.) until the fuel flow is free from air. Close the plug while the fuel is still flowing. NOTICE! Do not loosen the injectors delivery pipes. Electrical System Fuses The engine has automatic fuses located in the junction box. The fuses break the current when there is an overload in the electrical system. If the engine cannot be started or the instruments stop operating during operation, the fuse may have tripped. Reset the fuse by pressing on the button on the fuse. IMPORTANT Always investigate the cause of an overload before resetting the fuse! Battery WARNING! Risk of fire and explosion. Never allow an open flame or electric sparks near the battery or batteries. WARNING! Battery electrolyte is a corrosive acid and should be handled with care. If you spill or splash electrolyte on any part of the body, immediately flush the exposed area with liberal amounts of water and seek medical attention as soon as possible. WARNING! Ventilate the engine compartment before working on batteries 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 period of time, the batteries should be fully charged, trickle charged if possible. Maintenance It is important to always follow the battery manufacture’s recommendation and instruction when replacing and charging batteries. Depending on battery type the instructions for maintenance and charging may vary. Modern batteries are normally maintenance free, but there are some actions that are recommended to increase the battery service life and avoid accidents: • Keep the batteries clean and dry. Contamination and oxide on the batteries and battery poles can cause stray currents, voltage drop and discharge, especially in wet weather. • Remove oxidation from the battery poles and terminals, using a brass brush. • Tighten the terminals securely and grease them with terminal grease or petroleum jelly. Loose battery connections may cause damage to the engine’s electrical system. • Charge the battery regularly. A battery that is kept fully loaded has a maximum service life. The easiest way to check if a battery needs charging is to use a voltmeter. Volvo Engine Repair Instructions
Magnetically controlled proportional valve (MPROP) A magnetically controlled proportional valve (MPROP) controls the high pressure pump to ensure that the correct fuel pressure (rail pressure) is retained despite varying engine speed and loading. The input signal to the valve is a PWM signal whose pulse width is controlled by the engine control module. When the current through the valve is changed, this affects the fuel flow, which results in changed rail pressure. Water in fuel switch, secondary fuel filter A switch is located in the water trap under the fuel filter. Its task is to detect whether there is water in the fuel. The switch senses the resistance between two pins, wich are in contact with the fuel. When there is no water in the fuel, the resistance is very high. If there is any water in the fuel, the resistance falls. Switch, coolant level The task of the switch is to discover whether the coolant level in the engine (expansion tank) has become too low. An alarm signal is sent when the coolant level is too low. Preheater with preheater relay The preheater is located in the inlet manifold at the left side of the engine. The preheat relay is located at the engines left side beneath the preheater. Engine control unit, EMS 2 The engine control unit checks and controls the injectors, to ensure that the correct volume of fuel is injected into each cylinder at the right time. It also controls the high pressure pump via the proportional valve (MPROP) to ensure that the system always has the correct fuel pressure (rail pressure). The control unit also calculates and adjusts the injection advance. Regulation is mainly done with the aid of the engine speed sensor and the combined sensor for air inlet pressure/inlet manifold temperature. The EMS 2 system processor is located in the control unit, protected from water and vibration. The processor receives continuous information about: • Engine Speed • Throttle • Oil Pressure • Air inlet pressure/temperature • Fuel pressure (common rail pressure) • Fuel alarm, “Water in Fuel” • Camshaft position • Coolant temperature The information provides information about current operation conditions and allows the processor to calculate the correct fuel volume, monitor engine status etc. Repair Instructions General advice on working with EMS engines The following advice must be followed to avoid damage to the engine control unit and other electronics. IMPORTANT! The system must be disconnected from system voltage (by cutting the current with the main switch) and the starter key(s) must be in the 0 position when the engine control unit connectors are disconnected or connected. • Never disconnect the current with the main switches when an engine is running. • Never undo a battery cable when the engine is running. • Turn the main switches off or disconnect the battery cables during quick charging of the batteries. NOTICE! During normal trickle charging, it is not necessary to turn the main switches off. • Only batteries may be used for start help. A help start device can produce a very high voltage and damage the control unit and other electronics. • If a connector is disconnected from a sensor, be very careful to avoid allowing the contact pins to come into contact with oil, water or dirt. IMPORTANT! The system must be disconnected from system voltage when the engine control unit connectors are disconnected or connected. 2 Undo the two connectors from the engine control unit before any electrical welding starts. Turn the locking arm down at the same time as the connector is pulled outwards. 3 Disconnect all connections to the alternator. Connect the welder earth clamp to the component to be welded, or 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. IMPORTANT! After welding is completed, the disconnected components, such as alternator cables and battery cables must be connected in the correct order. The battery cables must always be connected last. Changing the engine control unit 1 NOTICE! Cut the current with the main switch. IMPORTANT! The system must be disconnected from system voltage when the engine control module connectors are disconnected or connected*. 2 Remove the two connectors from the engine control unit. Turn the locking arm down at the same time as the connector is pulled outwards 3 If the new engine control unit has recently been programmed: Start the engine and check whether any fault codes related to the engine control unit occur. Checking the starter motor voltage Tools: 88890074 Multimeter General If battery voltage falls below 24.7 V*, the starter motor will not be able to crank the engine at normal speed. A fully charged battery has an open circuit voltage of about 12.7 V. NOTICE! * Measured on the batteries. Voltage measurement, check 1 Check that the battery voltage is at least 24.7 V when unloaded by using 88890074 Multimeter to measure between the battery poles. 2 Turn the main switch on. 3 Check that the voltage between terminal B+ on the starter motor and battery negatives connection point is the same as the battery voltage. Checking the charging system Generally about alternators: The voltage output from an alternator must be limited to prevent the elecrolyte in the battery to evaporate. The alternator output is regulated (limited) by the voltage regulator in the alternator. The maximum current that the alternator can deliver at regulated voltage output depends on the alternator revolution. When the Volvo diesel engine is started an excitation current is needed to “wake up” the alternator. NOTICE! It is the consumers (batteries included) which decides the output current from the alternator. Diesel Engine Maintenance for Volvo Penta If you are a newcomer to diesel trucks, then you are likely also a newcomer to diesel engines. You may think that all DIY repairs on engines and engine maintenance is the same. The truth is that there are some changes between the diesel and gas engines. If you are considering taking on any of your diesel engine repair or maintenance yourself, then there are some tips that you should consider. Catalytic Converter Tips The catalytic converter helps to control emissions from the diesel engine into the air. It helps to control pollutants as well as toxic fumes and exhaust. If you think that you are having issues with your converter, you can check by using a vacuum gauge. This will let you know if it is working to proper standards. In addition to this check, you will also want to make sure that you do not have the heat shields in place during any maintenance or repair. It could cause a major meltdown of the system and further damage to the diesel engine. Start with Oil You may be hearing noises with your diesel engine that you would not find normal with a gas engine. You may be hearing knocking or even having hard starts with the engine. These hard starts are marked with a jolt-like sensation when you change gears or move. You may think that your diesel engine is having issues, when in fact it may be something easier than that. For this reason, you should start off with draining the oil and changing the filter. Though this can be said for any engine type, it is increasingly more important with a diesel engine. The reason is due to the multiple parts that help with emission controls that you may not find on gas engines. These parts and controls can get clogged easily with old oil and old fluids. By flushing the system and changing these fluids, you may find the issue is no longer there. Hard Start Tips The environment you are in can have a lot to do with how your diesel engine is operating. For example, if you are having a hard start issue with the diesel truck, you may be thinking that the engine itself is failing. The truth is that it just may be too cold for the engine to start properly. You can help this by installing an electrical heater in the engine. This will help keep the engine in a warmer state and help reduce the chances of cold start issues. By keeping these tips, and the information about them, in mind, you will be better prepared to step onto the DIY maintenance path. Remember, you may need additional parts, and some of those parts may require more knowledge than a simple DIY fix and books can offer. In these cases, be prepared to take the engine in for professional repair. Volvo Penta Engines This Operator's Manual covers the industrial engines: 4 cylinders TD520GE, TAD530GE, TAD531GE and TAD532GE. 6 cylinders TAD620VE, TAD730GE, TAD731GE, TAD732GE, TAD720VE and TAD721VE of Volvo Penta Engine. The engines are four-stroke, direct injection in-line diesel engines with replaceable wet cylinder liners (except TAD620VE, which has dry liners). The engines are fitted with turbochargers, piston cooling and a water-cooled charge air cooler that reduces the temperature of inlet air to provide a greater mass of air to the cylinders. This makes greater engine output possible at the same time as combustion and exhaust temperatures can be maintained at suitable levels. Also, NOx emissions are reduced. To facilitate start and reduce exhaust emissions in cold weather, the engines are fitted with electric intake air heaters (exceptions TAD520GE and TAD720VE). Instruments and Controls This chapter describes the instrument box and the instrumentation in Volvo Penta’s range. Variations in the appearance of instrumentation may occur in certain applications (mobile for example). If this is the case, see the Instruction Manual for the relevant application. Warning If the instrument box does not have an ignition switch, the engine/operator compartment must have a lock to prevent unauthorised persons starting the engine. (Alternatively a lockable main switch can be used.) Instrument box 1. Oil pressure gauge. Normally within the green field (300–500 kPa). 2. Warning lamp: Low engine coolant level (accessory) 3. Engine coolant temperature gauge. Normally within the green field (70–95°C). 4. Warning lamp: High engine coolant temperature (accessory) 5. Tachometer 6. Operating hour counter 7. Starter button 8. Warning lamp: Generator not charging 9. Interlock: Press in the button to disengage the automatic stop for low oil pressure and to activate preheating. 10. Warning lamp: Low oil pressure (accessory) 11. Stop button 12. Semi-automatic fuses: Reset by pressing the button on the fuse. Before Starting Check that the oil level is between the MIN and MAX marks. For filling refer to Oil level, checking and topping up. • Open the fuel cocks. • Check that there are no coolant, fuel or oil leaks. • Check the air filter pressure drop indicator. Please refer to Engine, General. • Check coolant level. Check that the outside of the radiator is not clogged. Please refer to Coolant Level, Checking and Topping Up, and Charge Air Cooler, External Cleaning. WARNING! Do not open the coolant filler cap when the engine is hot, except in emergencies as this could cause serious personal injury. Steam or hot fluid could spray out. • Turn the main switch on. IMPORTANT: Never break the circuit with the main switch while the engine is running. Alternator and electronics could be damaged. • Set the engine speed control to idle. Disengage the disengageable clutch/transmission. Starting the Engine 1. Press the “Interlock button” (1) and check that the warning lamps in the instrument box are functioning. (This applies to engines equipped with alarm separators). 2. If the engine is hot: Press the “Interlock button” (1) and hold it in while pressing the Starter button (2). If the engine is cold: Press the Interlock button (1) and hold it in for approximately 50 seconds to preheat the engine. Then press the “Start button” (2) as well. 3. Release the Start button immediately when the engine starts. However the Interlock button must be held down for a further 5 seconds approximately. This is to allow the oil pressure to reach the correct level. Otherwise the automatic stop will engage and stop the engine. NOTICE! In extreme cold, the preheating can be re-engaged for a few minutes after start if necessary. Hold the Interlock button (1) pressed in. |
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dieselgenerator 存档
July 2022
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